Polycarbonate resin composition and formed product thereof

ABSTRACT

In a polycarbonate resin composition containing a polycarbonate resin and a polycarbosilane compound, the use of the polycarbosilane compound modifies the surface properties of the polycarbonate resin composition without adversely affecting the intrinsic characteristics of the polycarbonate resin, such as transparency, heat resistance, and mechanical properties, e.g., impact resistance. A polycarbonate resin composition containing 100 parts by mass of a polycarbonate resin, 0.001 to 1 part by mass of a metal salt compound, and 0.005 to 5 parts by mass of a polycarbosilane compound has significantly improved flame resistance and high transparency and causes markedly reduced outgassing and mold fouling, without losing impact resistance and heat resistance.

This is a divisional application of U.S. application Ser. No. 13/840,034filed Mar. 15, 2013, which is a divisional application of U.S.application Ser. No. 13/139,229, filed Jun. 10, 2011, which is aNational Stage of PCT/JP2010/050089 filed on Jan. 7, 2010 all of whichare incorporated herein by reference. This application also claims thebenefit of JP 2009-026837 filed Feb. 9, 2009; JP 2009-055802 filed Mar.10, 2009; JP 2009-075456 filed Mar. 26, 2009; JP 2009-102103 filed Apr.20, 2009; JP 2009-102104 filed Apr. 20, 2009 and JP 2009-103168 filedApr. 21, 2009.

FIELD OF INVENTION

The present invention relates to a thermoplastic resin composition suchas a polycarbonate resin composition, and the formed product thereof.

BACKGROUND ART

Polycarbonate resins are resins having excellent heat resistance,mechanical properties, optical properties, and electricalcharacteristics and are widely utilized, for example, in automotivematerials, electrical and electronic device materials, housingmaterials, and materials for use in the manufacture of components inother industrial fields. In particular, flame-resistant polycarbonateresin compositions are suitably used as members for OA and informationappliances, such as computers, notebook computers, cellular phones,printers, and copying machines, and sheet and film members.

In these various applications, it is known to blend organosiloxane(silicone) compounds having low surface energy with resins to modifysurface properties, such as water repellency, oil repellency,anti-fogging properties, anti-fouling properties, stain removability,moisture resistance, lubricity, abrasion resistance, mold releasability,chemical resistance, and scratch resistance, for the purpose ofimproving product value. Among others, dimethyl silicone oils caneffectively impart water repellency, oil repellency, and othercharacteristics.

Furthermore, resin lubricants containing polysilane compounds have beenproposed (Patent Document 19).

As means for imparting flame resistance to polycarbonate resins, methodsfor blending a halogen flame retardant or a phosphorus flame retardantwith polycarbonate resins have been employed. However, polycarbonateresin compositions containing a halogen flame retardant containingchlorine or bromine sometimes result in low thermal stability ordeteriorated hue or cause the corrosion of screws or forming dies offorming machines in shape processing. Polycarbonate resin compositionscontaining a phosphorus flame retardant sometimes cause degradation ofhigh transparency that is characteristic of polycarbonate resins orresult in low impact resistance or low heat resistance, thus havinglimited applications. In addition, such a halogen flame retardant andphosphorus flame retardant may cause environmental pollution during thedisposal and collection of products. Thus, in recent years, it has beenstrongly desired to impart flame resistance to polycarbonate resinswithout using such a flame retardant.

Under such circumstances, many metal salt compounds, typically organicalkali metal salt compounds and organic alkaline-earth metal saltcompounds, have been recently studied as useful flame retardants (e.g.,refer to Patent Documents 1 to 4). Examples of methods for impartingflame resistance to aromatic polycarbonate resin compositions by usingan aromatic sulfonic acid alkali metal salt compound include a methodthat uses a perfluoroalkylsulfonic acid alkali metal salt having 4 to 8carbon atoms (refer to Patent Document 1) and a method for blending anon-halogen aromatic sulfonic acid sodium salt (refer to Patent Document2). Such metal salt compounds can be used as flame retardants to impartflame resistance to polycarbonate resins to some extent withoutadversely affecting their intrinsic characteristics such as mechanicalproperties, including impact resistance, heat resistance, opticalproperties, and electrical characteristics.

However, the flame resistance levels achieved by the above-describedmethods for blending such a metal salt compound with a polycarbonateresin are by no means satisfactory. This is probably because theflame-retardant effect achieved by blending the metal salt compound witha polycarbonate resin results from a catalytic action. Even if theamount of metal salt compound blended is increased to further improvethe flame resistance, the flame resistance is not improved and, on thecontrary, tends to be lowered. Furthermore, such an increase in theamount of metal salt compound causes a significant deterioration inmechanical properties, such as impact resistance, optical properties,such as transparency, and other physical properties, such as heatresistance and wet heat stability.

An attempt has been made to improve flame resistance by blending anorganosiloxane (silicone) compound with a polycarbonate resin (e.g.,refer to Patent Document 5).

In particular, methods for blending an organosiloxane compound having abranched structure in the main chain and having an aromatic group havebeen actively studied (e.g., refer to Patent Documents 6 to 8).

Furthermore, methods for simultaneously blending an organic sulfonicacid metal salt and the above-described organosiloxane compound having abranched structure in the main chain and having an aromatic group havebeen proposed (e.g., refer to Patent Documents 9 and 10).

However, the methods for blending only an organosiloxane compoundaccording to Patent Documents 5 to 8 practically have very small effectsof improving flame resistance and cannot achieve practical levels offlame resistance.

Furthermore, organosiloxane compounds have poor compatibility with anddispersibility in polycarbonate resins, resulting in poor mechanicalproperties, such as impact resistance, and thermophysical properties. Inaddition, even the addition of a small amount of organosiloxane compoundmarkedly lowers the transparency of polycarbonate resins, which presentsa critical drawback. Moreover, there are other problems such as thegeneration of a large amount of gas during kneading and shaping of resincompositions, a tendency to cause mold fouling, poor appearances ofresin formed products, and sticky surfaces.

In accordance with the methods for simultaneously blending an organicsulfonic acid metal salt and the organosiloxane compound, the methodsbeing proposed in Patent Documents 9 and 10, the amount oforganosiloxane compound to be blended can be relatively reduced toimprove flame resistance and thus the generation of gas, mold fouling,and poor appearances and stickiness of resin formed products can besuppressed to some extent. However, this cannot prevent deterioration inmechanical properties or thermophysical properties, particularlytransparency.

Examples of methods for improving transparency that have been proposedinclude a method in which an organosiloxane compound having a particularfunctional group is used to improve compatibility with polycarbonateresins (e.g., refer to Patent Documents 11 to 13), a method using anorganosiloxane compound having a phenyl group and a low degree ofpolymerization (e.g., refer to Patent Document 14), and a method using alow-molecular-weight organosiloxane compound (e.g., refer to PatentDocuments 15 and 16).

In accordance with recent studies, polysilanes having the main chaincomposed of silicon atoms are blended with resins to improve mechanicalproperties, lubricity, and flame resistance. (e.g., refer to PatentDocuments 17 to 19)

Hitherto, fluoropolymers have been blended with thermoplastic resins toimprove the melt properties and surface properties, such as slidingcharacteristics, scratch resistance, water repellency, oil repellency,stain resistance, and fingerprint resistance, of the thermoplasticresins.

Among others, fluoroolefin polymers capable of forming fibrils caneffectively modify the melt properties of thermoplastic resins. Inparticular, the blend of fluoroolefin polymers with flame-retardedthermoplastic resin compositions can improve anti-dripping propertiesduring combustion and thereby can prevent the spread of fire when athermoplastic resin formed product burns, thus showing excellentblending effects.

In the case where flame resistance is imparted to thermoplastic resins,fluoropolymers generally need to be used in combination with flameretardants because, normally, the addition of a fluoropolymer aloneimproves anti-dripping properties, but does not improve extinctionproperties (e.g., refer to Patent Documents 20 and 21).

In recent years, attempts have been actively made to weld thermoplasticresin formed products using a near-infrared laser (so-called laserwelding) in automobile, electrical and electronics, and precisionapparatus fields. Laser welding methods are noncontact methods, produceno abrasion powder or burrs, and cause minimal damage to products. Thus,laser welding methods have considerable industrial advantages.

Near-infrared light having a wavelength of 800 to 1200 nm is generallysuitably used as a laser for use in laser welding for safety and costreasons. Thus, thermoplastic resin compositions that are highlytransparent to light in the near-infrared region are used in a laserwelding field (e.g., refer to Patent Documents 22 and 23).

Many thermoplastic resin compositions are used in members for sensingdevices, exemplified by various automobile sensing devices, such as facedirection detection systems and rain sensors, various security systems,such as face recognition systems, fingerprint recognition systems, andvein recognition systems, and various information/communication devices,such as remote controllers and infrared communication devices. Thewavelength of infrared light used in such fields depends on the devicesand systems. In general, near-infrared light in the range of 800 to 1500nm is used. Thus, also in such fields, there is a demand forthermoplastic resin compositions that are highly transparent to light ina near-infrared region.

CITATION LIST Patent Document

-   Patent Document 1: Japanese Examined Patent Application Publication    No. 47-40445-   Patent Document 2: Japanese Examined Patent Application Publication    No. 54-32456-   Patent Document 3: Japanese Unexamined Patent Application    Publication No. 2000-169696-   Patent Document 4: Japanese Unexamined Patent Application    Publication No. 2001-181493-   Patent Document 5: Japanese Examined Patent Application Publication    No. 62-60421-   Patent Document 6: Japanese Patent No. 3240972-   Patent Document 7: Japanese Patent No. 3716754-   Patent Document 8: Japanese Patent No. 3835497-   Patent Document 9: Japanese Unexamined Patent Application    Publication No. 11-217494-   Patent Document 10: Japanese Unexamined Patent Application    Publication No. 11-263903-   Patent Document 11: Japanese Unexamined Patent Application    Publication No. 2004-524423-   Patent Document 12: Japanese Patent No. 3163596-   Patent Document 13: Japanese Patent No. 2719486-   Patent Document 14: Japanese Patent No. 2746519-   Patent Document 15: Japanese Patent No. 3503095-   Patent Document 16: Japanese Unexamined Patent Application    Publication No. 2003-531940-   Patent Document 17: Japanese Unexamined Patent Application    Publication No. 2003-268247-   Patent Document 18: Japanese Unexamined Patent Application    Publication No. 2003-277617-   Patent Document 19: Japanese Unexamined Patent Application    Publication No. 2003-277756-   Patent Document 20: Japanese Unexamined Patent Application    Publication No. 11-181265-   Patent Document 21: Japanese Unexamined Patent Application    Publication No. 2000-239509-   Patent Document 22: Japanese Unexamined Patent Application    Publication No. 2006-199861-   Patent Document 23: Japanese Unexamined Patent Application    Publication No. 2007-131692

OBJECT AND SUMMARY OF INVENTION Objects to be Achieved by InventionObject I

Hitherto, organosiloxane (silicone) compounds used to improve surfaceproperties, particularly dimethylsiloxane, are effective in improvingwater repellency or the like but tend to have poor compatibility withresins and markedly poor dispersibility in resins. Thus, the blend oforganosiloxane (silicone) compounds with resins causes a significantdeterioration in mechanical properties.

Furthermore, because of poor compatibility with resins, organosiloxane(silicone) compounds bleed during forming or from a formed product overtime, resulting in mold fouling, poor surface appearances, stickiness,or unsustainable water-repellent effects.

Polysilane compounds also inevitably cause a deterioration in mechanicalproperties, and resin compositions containing such polysilane compoundsare unsatisfactory.

In particular, the blend of these compounds having poor dispersibilityin and compatibility with resins with polycarbonate resins results indegradation of the intrinsic transparency of the polycarbonate resinsand also causes a significant deterioration in heat resistance andmechanical properties, such as impact resistance.

In accordance with a first aspect, the present invention provides apolycarbonate resin composition having surface properties, such as waterrepellency, oil repellency, anti-fogging properties, anti-foulingproperties, stain removability, moisture resistance, lubricity, abrasionresistance, mold releasability, chemical resistance, and scratchresistance, modified with a modifier having excellent dispersibility inand compatibility with a polycarbonate resin without adversely affectingthe intrinsic characteristics of the polycarbonate resin, such astransparency, heat resistance, and impact resistance, and apolycarbonate resin formed product manufactured by shaping thepolycarbonate resin composition (Object I).

Object II

Although the methods according to Patent Documents 11 to 16 can providerelatively high transparency, the organosiloxane compounds have stillinsufficient dispersibility in polycarbonate resins, often resulting inunstable flame resistance. Furthermore, since the organosiloxanecompounds having a low degree of polymerization or a low molecularweight are used to improve dispersibility, even the addition of a smallamount of organosiloxane compound tends to generate a large amount ofgas while kneading and shaping resin compositions and foul a metal mold.An increase in the amount of organosiloxane compound so as to achievestable flame resistance causes serious gas evolution and mold foulingproblems. Thus, the methods are unsatisfactory for practical use.

Such an organosiloxane compound deposited on a surface of a formedproduct or bleeding from a formed product can be responsible forelectrical troubles, such as contact failure, in electrical andelectronic applications. Thus, such an organosiloxane compound cannot beused.

Thus, it is significantly difficult to impart flame resistance topolycarbonate resins and suppress outgassing and mold fouling byblending organosiloxane compounds with the polycarbonate resins withoutadversely affecting the mechanical properties, thermophysicalproperties, and transparency of the polycarbonate resins.

Patent Document 17 proposes a resin composition blended with apolysilane compound, which is a silicon compound different fromorganosiloxane compounds. The polysilane compound also has poorcompatibility with and dispersibility in polycarbonate resins and cannotsuppress deterioration in mechanical properties, such as impactresistance, or transparency of the polycarbonate resins.

Thus, polycarbonate resin compositions having excellent flameresistance, shaping processability, mechanical properties, heatresistance, and transparency have not been manufactured.

In accordance with a second aspect, the present invention provides apolycarbonate resin composition that has excellent flame resistance andmechanical properties, such as impact resistance, causes very littleoutgassing and mold fouling, and has high transparency, and apolycarbonate resin formed product manufactured by shaping thepolycarbonate resin composition (Object II).

Object III

Fluoropolymers used to improve the melt properties or surface propertiesof thermoplastic resins have considerably poor compatibility with anddispersibility in the thermoplastic resins. The blend of even a smallamount of fluoropolymer therefore results in significantly lowered lighttransmittance or poor appearance.

In particular, with the recent demand for stricter fire prevention,there is a growing tendency to use flame-retarded thermoplastic resincompositions in electrical and electronic device components and membersfor sensing devices manufactured by laser welding described above. Useof thermoplastic resin compositions blended with fluoropolymers in suchfields significantly lowers light transmittance, particularly in anear-infrared region. This limits the application of the thermoplasticresin compositions, thus presenting a critical drawback.

For example, a decrease in the light transmittance in a near-infraredregion through a thermoplastic resin composition for laser weldingresults in a low transmittance of a laser beam and must be compensatedby a reduction in thickness. This narrows the degree of freedom ofproduct thickness design and tends to lower the product strength. Anincrease in laser output can cause problems. For example, defects, suchas fusion and fuming on a laser incident surface and bubbles caused byabnormal heat generation at a bonding interface, can make weldingimpossible. An increase in laser output can also result in poorappearance and strength reduction.

Likewise, in various sensing devices, a decrease in the lighttransmittance in a near-infrared region through a thermoplastic resincomposition constituting the sensing devices results in a significantreduction in the sensitivity of the sensing devices. A thicknessreduction to increase the transmittance of infrared light results inlower product strength and an increase in the transmittance atwavelengths other than the wavelength used, which also results in areduction in the sensitivity of the sensing devices and possibly causesmalfunctions.

Thus, there is a strong demand for a technique for improving thecompatibility and dispersibility of a fluoropolymer in a thermoplasticresin and thus increasing light transmittance in a near-infrared region.

In accordance with a third aspect, for the purpose of modifying the meltproperties and surface properties of thermoplastic resins, such assliding characteristics, abrasion resistance, water repellency, oilrepellency, stain resistance, and fingerprint resistance, the presentinvention provides a thermoplastic resin composition blended with afluoropolymer in which improvements have been made in the dispersibilityof the fluoropolymer in the thermoplastic resin and light transmittance,particularly light transmittance in a near-infrared region, as well asflame resistance, appearance, and strength, and also provides athermoplastic resin formed product manufactured by shaping thethermoplastic resin composition (Object III).

Object IV

The flame resistance of polycarbonate resins imparted by metal saltcompounds is catalytic. An increase in the amount of metal salt compoundto improve flame resistance is therefore not effective or even lowersflame resistance. Since the blend of polysilanes has a very smallflame-retardant effect, polycarbonate resin compositions blended withpolysilanes are unsatisfactory for practical use.

In accordance with a fourth aspect, the present invention provides apolycarbonate resin composition whose flame resistance and flowabilitycan be improved and a polycarbonate resin formed product manufactured byshaping the polycarbonate resin composition (Object IV).

Objects V and VI

The flame resistance of polycarbonate resins imparted by metal saltcompounds is catalytic. An increase in the amount of metal salt compoundto improve flame resistance is therefore not effective or even lowersflame resistance.

It is presumed that a flame retardation technique using metal saltcompounds is achieved by a carbonization promoting effect duringcombustion. In the case of thin-walled formed products, however, metalsalt compounds also have a decomposition promoting effect duringcombustion, as well as the carbonization promoting effect, therebyincreasing dripping.

In general, an electrical and electronic device field requires V-1 orhigher flame resistance in the UL 94 Test specified by the U.S.A.Underwriters Laboratories (UL). This requirement involves thesuppression of dripping during combustion.

Thus, fluoropolymers are generally blended to enhance anti-drippingproperties during combustion. However, even with the combination of ametal salt compound and a fluoropolymer, the thin-walled formed productsdescribed above cannot have sufficient flame resistance.

Since the blend of such polysilanes has a very small flame-retardanteffect, polycarbonate resin compositions blended with the polysilanesare unsatisfactory for practical use.

In accordance with a fifth aspect, the present invention provides apolycarbonate resin composition that can exhibit reduced dripping duringcombustion and has high flame resistance even in the case of thin-walledformed products, and a polycarbonate resin formed product manufacturedby shaping the polycarbonate resin composition (Object V).

In accordance with a sixth aspect, the present invention provides apolycarbonate resin composition having high flame resistance, as well ashigh transparency, excellent hue, and high impact resistance, and apolycarbonate resin formed product manufactured by shaping thepolycarbonate resin composition (Object VI).

SUMMARY OF INVENTION

In order to achieve Object I, the present inventor has focused on themolecular structure, particularly the structure of the main chain, of amodifier to be blended with polycarbonate resins and has conductedextensive studies thereon.

As a result, the present inventor has completed the first aspect of thepresent invention by finding that a polycarbosilane compound can beblended as a modifier for a polycarbonate resin to modify surfaceproperties, such as water repellency, oil repellency, anti-foggingproperties, anti-fouling properties, stain removability, moistureresistance, lubricity, abrasion resistance, mold releasability, chemicalresistance, and scratch resistance, without adversely affecting theintrinsic characteristics of the polycarbonate resin, such astransparency and impact resistance.

The first aspect of the present invention includes a polycarbonate resincomposition containing a polycarbonate resin and a polycarbosilanecompound, a polycarbonate resin formed product manufactured by shapingthe polycarbonate resin composition, and a modifier for polycarbonateresins, the modifier containing a polycarbosilane compound.

In order to achieve Object II, the present inventor has focused on themolecular structure, particularly the structure of the main chain, of asilicon compound to be blended with polycarbonate resins and hasconducted extensive studies thereon.

As a result, the present inventor has completed the second aspect of thepresent invention by finding that predetermined amounts of a metal saltcompound and an organosilicon compound having a predetermined structurecan be blended with a polycarbonate resin to achieve markedly improvedflame resistance, very little outgassing and mold fouling, and hightransparency, without losing impact resistance and heat resistance.

The second aspect of the present invention includes a polycarbonateresin composition containing 100 parts by mass of a polycarbonate resin,0.001 to 1 part by mass of a metal salt compound, and 0.005 to 5 partsby mass of a polycarbosilane compound, and a polycarbonate resin formedproduct manufactured by shaping the polycarbonate resin composition.

As a result of extensive studies in view of Object III, the presentinventor has completed the third aspect of the present invention byfinding that, in a thermoplastic resin composition containing afluoropolymer and blended with a polycarbosilane compound, thepolycarbosilane compound can effectively function as a fluoropolymerdispersant, improve the compatibility and dispersibility of thefluoropolymer in the thermoplastic resin, increase the lighttransmittance of a thermoplastic resin composition in a near-infraredregion, improve flame resistance, and solve poor appearance and strengthreduction.

The third aspect of the present invention includes a thermoplastic resincomposition containing a thermoplastic resin, a fluoropolymer, and afluoropolymer dispersant, wherein the fluoropolymer dispersant containsa polycarbosilane compound, and a thermoplastic resin formed productmanufactured by shaping the thermoplastic resin composition.

As a result of extensive studies to achieve Object IV, the presentinventor has completed the fourth aspect of the present invention byfinding that the addition of predetermined amounts of a metal saltcompound and a polysilane compound to a polycarbonate resin can markedlyimprove flame resistance and also improve flowability.

The fourth aspect of the present invention includes a polycarbonateresin composition containing 100 parts by mass of a polycarbonate resin,0.01 to 1 part by mass of a metal salt compound, and 0.01 to 5 parts bymass of a polysilane, and a polycarbonate resin formed productmanufactured by shaping the polycarbonate resin composition.

As a result of extensive studies to achieve Object V, the presentinventor has completed the fifth aspect of the present invention byfinding that the addition of predetermined amounts of a metal saltcompound, a fluoropolymer, and a polysilane compound to a polycarbonateresin can improve anti-dripping properties during combustion andmarkedly improve flame resistance.

The fifth aspect of the present invention includes a polycarbonate resincomposition containing 100 parts by mass of a polycarbonate resin, 0.001to 1 part by mass of a metal salt compound, 0.001 to 1 part by mass of afluoropolymer, and 0.01 to 2 parts by mass of a polysilane, and apolycarbonate resin formed product manufactured by shaping thepolycarbonate resin composition.

As a result of extensive studies to achieve Object VI, the presentinventor has completed the sixth aspect of the present invention byfinding that the addition of predetermined amounts of a metal saltcompound and a polysilane compound to a polycarbonate resin can markedlyimprove flame resistance, and use of a particular polysilane, morespecifically a polysilane having an aryl group, can provide apolycarbonate resin composition having excellent transparency, hue, andimpact resistance.

The sixth aspect of the present invention includes a polycarbonate resincomposition containing 100 parts by mass of a polycarbonate resin, 0.01to 1 part by mass of a metal salt compound, and 0.3 to 5 parts by massof a polysilane having an aryl group, and a polycarbonate resin formedproduct manufactured by shaping the polycarbonate resin composition.

Advantageous Effects of Invention Advantageous Effect I

The polycarbonate resin composition containing a polycarbosilanecompound as a modifier according to the first aspect of the presentinvention has excellent surface properties, such as water repellency,oil repellency, anti-fogging properties, anti-fouling properties, stainremovability, moisture resistance, lubricity, abrasion resistance, moldreleasability, chemical resistance, and scratch resistance whileretaining the intrinsic characteristics of polycarbonate resins, such astransparency, heat resistance, and impact resistance.

Unlike organosiloxane (silicone) compounds or polysilane compounds thathave been conventionally used as surface modifiers, polycarbosilanecompounds have high dispersibility in and compatibility withpolycarbonate resins, cause no bleedout problem, and do not adverselyaffect the intrinsic characteristics of polycarbonate resins.

The polycarbonate resin formed product according to the first aspect ofthe present invention has excellent transparency, mechanical properties,such as impact resistance, and heat resistance, modified surfaceproperties, such as water repellency, oil repellency, anti-foggingproperties, anti-fouling properties, stain removability, moistureresistance, lubricity, abrasion resistance, mold releasability, chemicalresistance, and scratch resistance, causes no outgassing or mold foulingproblem, can be manufactured with high productivity and high yield, andis industrially very useful as an automotive material, an electrical andelectronic device material, a housing material, or a material for use inthe manufacture of components in other industrial fields, particularlyas a member for OA and information appliances, such as computers,notebook computers, cellular phones, printers, and copying machines, ora sheet or film member.

Advantageous Effect II

The polycarbonate resin composition according to the second aspect ofthe present invention contains a metal salt compound effective inimproving flame resistance and, together with this metal salt compound,a polycarbosilane compound, and thereby can further improve flameresistance without adversely affecting mechanical properties, such asimpact resistance, transparency, and other physical properties andwithout causing outgassing and mold fouling problems.

Unlike organosiloxane (silicone) compounds or polysilane compounds thathave been conventionally used in combination with metal salt compounds,even the addition of a relatively large amount of polycarbosilanecompound to a polycarbonate resin does not adversely affect impactresistance, heat resistance, or transparency and causes littleoutgassing or mold fouling. Thus, use of a polycarbosilane compound incombination with a metal salt compound can provide a polycarbonate resincomposition that has high flame resistance and impact resistance, causesvery little outgassing and mold fouling, and has high transparency.

The polycarbonate resin formed product according to the second aspect ofthe present invention has excellent flame resistance, mechanicalproperties, such as impact resistance, and heat resistance, as well ashigh transparency, causes no outgassing or mold fouling problem, can bemanufactured with high productivity and high yield, and is industriallyvery useful as an automotive material, an electrical and electronicdevice material, a housing material, or a material for use in themanufacture of components in other industrial fields, particularly as amember for OA and information appliances, such as computers, notebookcomputers, cellular phones, printers, and copying machines, or a sheetor film member.

Advantageous Effect III

A polycarbosilane compound can effectively function as a dispersant fora fluoropolymer blended with a thermoplastic resin, improve thecompatibility and dispersibility of the fluoropolymer in thethermoplastic resin composition, and thereby prevent poor appearance andstrength reduction, and can also improve light transmittance,particularly near-infrared light transmittance, and even flameresistance.

The thermoplastic resin formed product manufactured by shaping thethermoplastic resin composition according to the third aspect of thepresent invention has melt properties and surface properties, such assliding characteristics, abrasion resistance, water repellency, oilrepellency, stain resistance, and fingerprint resistance, improved bythe blend of the fluoropolymer, has high light transmittance,particularly near-infrared light transmittance, and high flameresistance, and is industrially very useful as a member fornear-infrared laser welding or a member for sensing devices, exemplifiedby various automobile sensing devices, such as face direction detectionsystems and rain sensors, various security systems, such as facerecognition systems, fingerprint recognition systems, and veinrecognition systems, and various information communication devices, suchas remote controllers and infrared communication devices in automobile,electrical and electronic, and other precision apparatus fields.

Advantageous Effect IV

The polycarbonate resin composition according to the fourth aspect ofthe present invention can achieve higher flame resistance andflowability than before.

Advantageous Effect V

The polycarbonate resin composition according to the fifth aspect of thepresent invention can achieve higher flame resistance than before.

Advantageous Effect VI

The polycarbonate resin composition according to the sixth aspect of thepresent invention can achieve higher flame resistance, transparency, andimpact resistance than before.

DESCRIPTION OF EMBODIMENTS

The present invention will be described in detail in the followingembodiments and examples. However, the present invention is not limitedto these embodiments and examples, and any modification can be madewithout departing from the gist of the present invention.

I. First Aspect of the Present Invention 1. Overview

A polycarbonate resin composition according to the first aspect of thepresent invention contains at least a polycarbonate resin and apolycarbosilane compound. The polycarbonate resin composition accordingto the first aspect of the present invention may optionally containother components.

Polycarbosilane compounds are compounds having two or more repeatingunits each having a silicon-carbon bond (Si—C bond) in their mainchains. The polycarbosilane compound used in the first aspect of thepresent invention has the Si—C bond in its main chain and thus hasexcellent dispersibility in and compatibility with polycarbonate resins.Consequently, there can be solved the problems of existing polycarbonateresin compositions containing an organosiloxane (silicone) compound or apolysilane compound, such as degradations of transparency, impactresistance, and heat resistance, and outgassing and mold fouling.

2. Polycarbonate Resin

There is no limitation on the type of polycarbonate resin used in thepolycarbonate resin composition according to the first aspect of thepresent invention. Polycarbonate resins may be used alone, or two ormore polycarbonate resins may be combined with each other at any ratio.

The polycarbonate resin in the first aspect of the present invention isa polymer having a basic structure with a carbonate bond represented bythe following formula (7).

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins can be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

[2-1. Dihydroxy Compound]

Among dihydroxy compounds serving as a raw material of the polycarbonateresin, examples of aromatic dihydroxy compounds serving as a rawmaterial of the aromatic polycarbonate resin include:

-   dihydroxybenzenes, such as-   1,2-dihydroxybenzene,-   1,3-dihydroxybenzene (or resorcinol), and-   1,4-dihydroxybenzene,-   dihydroxybiphenyls, such as-   2,5-dihydroxybiphenyl,-   2,2′-dihydroxybiphenyl, and-   4,4′-dihydroxybiphenyl,-   dihydroxynaphthalenes, such as-   2,2′-dihydroxy-1,1′-binaphthyl,-   1,2-dihydroxynaphthalene,-   1,3-dihydroxynaphthalene,-   2,3-dihydroxynaphthalene,-   1,6-dihydroxynaphthalene,-   2,6-dihydroxynaphthalene,-   1,7-dihydroxynaphthalene, and-   2,7-dihydroxynaphthalene,-   dihydroxydiaryl ethers, such as-   2,2′-dihydroxydiphenyl ether,-   3,3′-dihydroxydiphenyl ether,-   4,4′-dihydroxydiphenyl ether,-   4,4′-dihydroxy-3,3′-dimethyldiphenyl ether,-   1,4-bis(3-hydroxyphenoxy)benzene, and-   1,3-bis(4-hydroxyphenoxy)benzene,-   bis(hydroxyaryl)alkanes, such as-   2,2-bis(4-hydroxyphenyl)propane (or bisphenol A),-   1,1-bis(4-hydroxyphenyl)propane,-   2,2-bis(3-methyl-4-hydroxyphenyl)propane,-   2,2-bis(3-methoxy-4-hydroxyphenyl)propane,-   2-(4-hydroxyphenyl)-2-(3-methoxy-4-hydroxyphenyl)propane,-   1,1-bis(3-tert-butyl-4-hydroxyphenyl)propane,-   2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane,-   2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane,-   2-(4-hydroxyphenyl)-2-(3-cyclohexyl-4-hydroxyphenyl)propane,-   α,α′-bis(4-hydroxyphenyl)-1,4-diisopropylbenzene,-   1,3-bis[2-(4-hydroxyphenyl)-2-propyl]benzene,-   bis(4-hydroxyphenyl)methane,-   bis(4-hydroxyphenyl)cyclohexylmethane,-   bis(4-hydroxyphenyl)phenylmethane,-   bis(4-hydroxyphenyl)(4-propenylphenyl)methane,-   bis(4-hydroxyphenyl)diphenylmethane,-   bis(4-hydroxyphenyl)naphthylmethane,-   1,1-bis(4-hydroxyphenyl)ethane,-   1,2-bis(4-hydroxyphenyl)ethane,-   1,1-bis(4-hydroxyphenyl)-1-phenylethane,-   1,1-bis(4-hydroxyphenyl)-1-naphthylethane,-   1,1-bis(4-hydroxyphenyl)butane,-   2,2-bis(4-hydroxyphenyl)butane,-   2,2-bis(4-hydroxyphenyl)pentane,-   1,1-bis(4-hydroxyphenyl)hexane,-   2,2-bis(4-hydroxyphenyl)hexane,-   1,1-bis(4-hydroxyphenyl)octane,-   2,2-bis(4-hydroxyphenyl)octane,-   1-bis(4-hydroxyphenyl)hexane,-   2-bis(4-hydroxyphenyl)hexane,-   4,4-bis(4-hydroxyphenyl)heptane,-   2,2-bis(4-hydroxyphenyl)nonane,-   1,10-bis(4-hydroxyphenyl)decane, and-   1,1-bis(4-hydroxyphenyl)dodecane,-   bis(hydroxyaryl)cycloalkanes, such as-   1,1-bis(4-hydroxyphenyl)cyclopentane,-   1,1-bis(4-hydroxyphenyl)cyclohexane,-   1,4-bis(4-hydroxyphenyl)cyclohexane,-   1,1-bis(4-hydroxyphenyl)-3,3-dimethylcyclohexane,-   1,1-bis(4-hydroxyphenyl)-3,4-dimethylcyclohexane,-   1,1-bis(4-hydroxyphenyl)-3,5-dimethylcyclohexane,-   1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane,-   1,1-bis(4-hydroxy-3,5-dimethylphenyl)-3,3,5-trimethylcyclohexane,-   1,1-bis(4-hydroxyphenyl)-3-propyl-5-methylcyclohexane,-   1,1-bis(4-hydroxyphenyl)-3-tert-butyl-cyclohexane,-   1,1-bis(4-hydroxyphenyl)-4-tert-butyl-cyclohexane,-   1,1-bis(4-hydroxyphenyl)-3-phenylcyclohexane, and-   1,1-bis(4-hydroxyphenyl)-4-phenylcyclohexane,-   bisphenols having a cardo structure, such as-   9,9-bis(4-hydroxyphenyl)fluorene, and-   9,9-bis(4-hydroxy-3-methylphenyl)fluorene,-   dihydroxydiaryl sulfides, such as-   4,4′-dihydroxydiphenyl sulfide, and-   4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfide,-   dihydroxydiaryl sulfoxides, such as-   4,4′-dihydroxydiphenyl sulfoxide, and-   4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfoxide, and-   dihydroxydiarylsulfones, such as-   4,4′-dihydroxydiphenylsulfone, and-   4,4′-dihydroxy-3,3′-dimethyldiphenylsulfone.

Among these, bis(hydroxyaryl)alkanes are preferred, andbis(4-hydroxyphenyl)alkanes are more preferred. In particular,2,2-bis(4-hydroxyphenyl)propane (or bisphenol A) is preferred in termsof impact resistance and heat resistance.

These aromatic dihydroxy compounds may be used alone, or two or more ofthe aromatic dihydroxy compounds may be combined with each other at anyratio.

Examples of aliphatic dihydroxy compounds serving as a raw material ofthe aliphatic polycarbonate resin include:

-   alkanediols, such as-   ethane-1,2-diol,-   propane-1,2-diol,-   propane-1,3-diol,-   2,2-dimethylpropane-1,3-diol,-   2-methyl-2-propylpropane-1,3-diol,-   butane-1,4-diol,-   pentane-1,5-diol,-   hexane-1,6-diol, and-   decane-1,10-diol,-   cycloalkanediols, such as-   cyclopentane-1,2-diol,-   cyclohexane-1,2-diol,-   cyclohexane-1,4-diol,-   1,4-cyclohexanedimethanol,-   4-(2-hydroxyethyl)cyclohexanol, and-   2,2,4,4-tetramethyl-cyclobutane-1,3-diol,-   glycols, such as-   2,2′-oxydiethanol (or ethylene glycol),-   diethylene glycol,-   triethylene glycol,-   propylene glycol, and-   spiroglycol,-   aralkyl diols, such as-   1,2-benzenedimethanol,-   1,3-benzenedimethanol,-   1,4-benzenedimethanol,-   1,4-benzenediethanol,-   1,3-bis(2-hydroxyethoxy)benzene,-   1,4-bis(2-hydroxyethoxy)benzene,-   2,3-bis(hydroxymethyl)naphthalene,-   1,6-bis(hydroxyethoxy)naphthalene,-   4,4′-biphenyldimethanol,-   4,4′-biphenyldiethanol,-   1,4-bis(2-hydroxyethoxy)biphenyl,-   bisphenol A bis(2-hydroxyethyl)ether, and-   bisphenol S bis(2-hydroxyethyl)ether, and-   cyclic ethers, such as-   1,2-epoxyethane (or ethylene oxide),-   1,2-epoxypropane (or propylene oxide),-   1,2-epoxycyclopentane,-   1,2-epoxycyclohexane,-   1,4-epoxycyclohexane,-   1-methyl-1,2-epoxycyclohexane,-   2,3-epoxynorbornane, and-   1,3-epoxypropane.

These aliphatic dihydroxy compounds may be used alone, or two or more ofthe aliphatic dihydroxy compounds may be combined with each other at anyratio.

[2-2. Carbonate Precursor]

Among monomers serving as a raw material of the polycarbonate resin,examples of the carbonate precursor include carbonyl halides andcarbonate esters.

These carbonate precursors may be used alone, or two or more of thecarbonate precursors may be combined with each other at any ratio.

Specific examples of carbonyl halides include phosgene and haloformates,such as bischloroformates of dihydroxy compounds and monochloroformatesof dihydroxy compounds.

Specific examples of carbonate esters include diaryl carbonates, such asdiphenyl carbonate and ditolyl carbonate; dialkyl carbonates, such asdimethyl carbonate and diethyl carbonate; and carbonates of dihydroxycompounds, such as biscarbonates of dihydroxy compounds, monocarbonatesof dihydroxy compounds, and cyclic carbonates.

[2-3. Method for Producing Polycarbonate Resin]

A method for producing a polycarbonate resin is not particularly limitedand may be any method. Examples of the method include an interfacialpolymerization method, a melt transesterification method, a pyridinemethod, a ring-opening polymerization method of cyclic carbonatecompounds, and a solid phase transesterification method of prepolymers.Among these, particularly suitable methods are more specificallydescribed below.

<Interfacial Polymerization Method>

An interfacial polymerization method for producing polycarbonate resinsis described below. In accordance with the interfacial polymerizationmethod, a dihydroxy compound and a carbonate precursor (preferablyphosgene) are allowed to react with each other in the presence of anorganic solvent inert to the reaction and an aqueous alkaline solutionnormally at a pH of 9 or more, and subsequent interfacial polymerizationin the presence of a polymerization catalyst yields a polycarbonateresin. If necessary, the reaction system may include a molecular weightmodifier (terminating agent) and an antioxidant for preventing theoxidation of the dihydroxy compound.

Dihydroxy compounds and carbonate precursors to be used are describedabove. Among the carbonate precursors, phosgene is preferably used. Amethod using phosgene is particularly referred to as a phosgene method.

Examples of the organic solvent inert to the reaction includechlorinated hydrocarbons, such as dichloromethane, 1,2-dichloroethane,chloroform, monochlorobenzene, and dichlorobenzene; and aromatichydrocarbons, such as benzene, toluene, and xylene. These organicsolvents may be used alone, or two or more of the organic solvents maybe combined with each other at any ratio.

Examples of an alkaline compound contained in the aqueous alkalinesolution include alkali metal compounds and alkaline-earth metalcompounds, such as sodium hydroxide, potassium hydroxide, lithiumhydroxide, and sodium hydrogen carbonate. Among these, sodium hydroxideand potassium hydroxide are preferred. These alkaline compounds may beused alone, or two or more of the alkaline compounds may be combinedwith each other at any ratio.

The concentration of the alkaline compound in the aqueous alkalinesolution is not particularly limited and generally ranges from 5% to 10%by mass to control the pH of the reaction system within the range of 10to 12. For example, in the case of blowing with phosgene, in order tocontrol the pH of an aqueous phase within the range of 10 to 12,preferably 10 to 11, it is preferable that the molar ratio of thedihydroxy compound to the alkaline compound is generally 1:1.9 or more,particularly 1:2.0 or more, and generally 1:3.2 or less, particularly1:2.5 or less.

Examples of the polymerization catalyst include aliphatic tertiaryamines, such as trimethylamine, triethylamine, tributylamine,tripropylamine, and trihexylamine; alicyclic tertiary amines, such asN,N′-dimethylcyclohexylamine and N,N′-diethylcyclohexylamine; aromatictertiary amines, such as N,N′-dimethylaniline and N,N′-diethylaniline;quaternary ammonium salts, such as trimethylbenzylammonium chloride,tetramethylammonium chloride, and triethylbenzylammonium chloride;pyridine; guanine; and salts of guanidine. These polymerizationcatalysts may be used alone, or two or more of the polymerizationcatalysts may be combined with each other at any ratio.

Examples of the molecular weight modifier include aromatic phenolshaving a monovalent phenolic hydroxy group; aliphatic alcohols, such asmethanol and butanol; mercaptans; and phthalimide. Among these, aromaticphenols are preferred. Specific examples of the aromatic phenols includealkyl-substituted phenols, such as m-methylphenol, p-methylphenol,m-propylphenol, p-propylphenol, p-tert-butylphenol, andp-long-chain-alkyl-substituted phenols; phenols having a vinyl group,such as isopropanylphenol; phenols having an epoxy group; and phenolshaving a carboxyl group, such as o-oxybenzoic acid and2-methyl-6-hydroxyphenylacetic acid. These molecular weight modifiersmay be used alone, or two or more of the molecular weight modifiers maybe combined with each other at any ratio.

The amount of molecular weight modifier to be used is generally 0.5 molor more and preferably 1 mol or more and generally 50 mol or less andpreferably 30 mol or less relative to 100 mol of the dihydroxy compound.By setting the amount of molecular weight modifier to be used within therange, the thermal stability and hydrolysis resistance of thepolycarbonate resin composition can be improved.

In the reaction, a reaction substrate, a reaction medium, a catalyst,and an additive agent are mixed in any order provided that a desiredpolycarbonate resin can be produced. Thus, the order may beappropriately determined. For example, when phosgene is used as thecarbonate precursor, the molecular weight modifier may be added at anypoint between the reaction (phosgenation) of the dihydroxy compound withphosgene and the beginning of the polymerization reaction.

The reaction temperature generally ranges from 0° C. to 40° C., and thereaction time generally ranges from several minutes (for example, 10minutes) to several hours (for example, 6 hours).

<Melt Transesterification Method>

A melt transesterification method for producing polycarbonate resins isdescribed below. The melt transesterification method involves, forexample, transesterification between a carbonic acid diester and adihydroxy compound.

Dihydroxy compounds to be used are described above.

Examples of the carbonic acid diester include dialkyl carbonatecompounds, such as dimethyl carbonate, diethyl carbonate, anddi-tert-butyl carbonate; diphenyl carbonate; and substituted diphenylcarbonates, such as ditolyl carbonate. Among these, diphenyl carbonateand substituted diphenyl carbonates are preferred, and particularlydiphenyl carbonate is more preferred. These carbonic acid diesters maybe used alone, or two or more of the carbonic acid diesters may becombined with each other at any ratio.

The ratio of the dihydroxy compound to the carbonic acid diester is notparticularly limited provided that a desired polycarbonate resin can beproduced. Preferably 1 or more, more preferably 1.01 or more, mol of thecarbonic acid diester is used relative to 1 mol of the dihydroxycompound. The upper limit is generally 1.30 mol or less. Within therange, the number of terminal hydroxy groups can be controlled within asuitable range.

In polycarbonate resins, the number of terminal hydroxy groups tends tosignificantly affect their thermal stability, hydrolytic stability, andcolor tone. Therefore, the number of terminal hydroxy groups may beoptionally controlled by a known method. In transesterification, themixing ratio of the carbonic acid diester to the dihydroxy compound andthe degree of vacuum in transesterification are generally controlled toproduce a polycarbonate resin having a controlled number of terminalhydroxy groups. In general, this procedure also allows the control ofthe molecular weights of polycarbonate resins produced.

When the number of terminal hydroxy groups is controlled using themixing ratio of the carbonic acid diester to the dihydroxy compound, themixing ratio is as described above.

A more active control method is a method in which a terminating agent isseparately mixed during the reaction. Examples of the terminating agentinclude monovalent phenols, monovalent carboxylic acids, and carbonicacid diesters. These terminating agents may be used alone, or two ormore of the terminating agents may be combined with each other at anyratio.

The production of polycarbonate resins by the melt transesterificationmethod generally employs a transesterification catalyst. Anytransesterification catalyst may be used. Among others, for example, analkali metal compound and/or an alkaline-earth metal compound ispreferably used. In an auxiliary manner, for example, a basic compound,such as a basic boron compound, a basic phosphorus compound, a basicammonium compound, or an amine compound, may be used together. Thesetransesterification catalysts may be used alone, or two or more of thetransesterification catalysts may be combined with each other at anyratio.

In the melt transesterification method, the reaction temperaturegenerally ranges from 100° C. to 320° C. The reaction pressure isgenerally a reduced pressure of 2 mmHg or less. Specifically, a meltpolycondensation reaction may be performed under the conditionsdescribed above while removing by-products, such as an aromatic hydroxycompound.

The melt polycondensation reaction may be performed batchwise orcontinuously. In a batchwise reaction, a reaction substrate, a reactionmedium, a catalyst, and an additive agent are mixed in any orderprovided that a desired aromatic polycarbonate resin can be produced.Thus, the order may be appropriately determined. In consideration of thestability or the like of polycarbonate resins and polycarbonate resincompositions produced, the melt polycondensation reaction is preferablyperformed continuously.

The melt transesterification method may optionally employ a catalystdeactivator. The catalyst deactivator may be any compound that canneutralize the transesterification catalyst. Examples of the catalystdeactivator include sulfur-containing acidic compounds and thederivatives thereof. These catalyst deactivators may be used alone, ortwo or more of the catalyst deactivators may be combined with each otherat any ratio.

The amount of catalyst deactivator to be used is generally 0.5equivalents or more and preferably 1 equivalent or more and generally 10equivalents or less and preferably 5 equivalents or less with respect toan alkali metal or alkaline-earth metal contained in thetransesterification catalyst. The amount of catalyst deactivator to beused is generally 1 ppm or more and generally 100 ppm or less andpreferably 20 ppm or less with respect to the polycarbonate resin.

[2-4. Other Matters regarding Polycarbonate Resin]

The molecular weight of the polycarbonate resin used in the first aspectof the present invention is not particularly limited and may beappropriately determined. The viscosity-average molecular weight [Mv]converted from the solution viscosity is generally 10000 or more,preferably 16000 or more, and more preferably 18000 or more andgenerally 40000 or less and preferably 30000 or less. Theviscosity-average molecular weight not less than the above-describedlower limit results in improved mechanical strength of the polycarbonateresin composition according to the first aspect of the presentinvention. This is therefore more preferred in applications that requirehigh mechanical strength. The viscosity-average molecular weight notmore than the above-described upper limit results in the suppression ofreduction in the flowability of the polycarbonate resin compositionaccording to the first aspect of the present invention, improvingshaping processability and facilitating shape processing. Two or morepolycarbonate resins having different viscosity-average molecularweights may be used in combination. In this case, polycarbonate resinshaving viscosity-average molecular weights outside the suitable rangedescribed above may be mixed.

The viscosity-average molecular weight [Mv] is a value determined bymeasuring the intrinsic viscosity [η] (dl/g) with an Ubbelohdeviscometer at a temperature of 20° C. using methylene chloride as asolvent and calculating Mv from the Schnell's viscosity equationη=1.23×10⁻⁴Mv^(0.83). The intrinsic viscosity [η] is a value determinedby measuring the specific viscosities [η_(sp)] at different solutionconcentrations [C] (g/dl) and calculating η from the following formula.

$\eta = {\lim\limits_{c\rightarrow 0}\; {\eta_{sp}\text{/}c}}$

The terminal hydroxyl group concentration of the polycarbonate resin isnot particularly limited and may be appropriately determined. Theterminal hydroxyl group concentration of the polycarbonate resin isgenerally 1000 ppm or less, preferably 800 ppm or less, and morepreferably 600 ppm or less. The terminal hydroxyl group concentrationnot more than the upper limit results in further improved thermalstability in residence and color tone of the polycarbonate resincomposition according to the first aspect of the present invention. Thelower limit, particularly for polycarbonate resins produced by the melttransesterification method, is generally 10 ppm or more, preferably 30ppm or more, and more preferably 40 ppm or more. The terminal hydroxylgroup concentration not less than the lower limit results in thesuppression of reduction in the molecular weight and further improvedmechanical properties of the polycarbonate resin composition accordingto the first aspect of the present invention.

The terminal hydroxyl group concentration is the weight ratio of theterminal hydroxyl group to the polycarbonate resin expressed in ppm. Themeasurement method of the terminal hydroxyl group concentration iscolorimetry that uses a titanium tetrachloride/acetic acid method (amethod described in Macromol. Chem. 88 215 (1965)).

The polycarbonate resin may be a polycarbonate resin alone (the term “apolycarbonate resin alone” includes not only an aspect involving onlyone type of polycarbonate resin, but also an aspect involving multipletypes of polycarbonate resins, for example, having different monomercompositions, molecular weights, or physical properties) or may be analloy (mixture) of a polycarbonate resin and another thermoplasticresin. For example, the polycarbonate resin may be a copolymer mainlycomposed of a polycarbonate resin: for example, for the purpose offurther improving flame resistance and impact resistance, a copolymerwith an oligomer or polymer having a siloxane structure; for the purposeof further improving thermo-oxidative stability and flame resistance, acopolymer with a monomer, oligomer, or polymer having a phosphorus atom;for the purpose of improving thermo-oxidative stability, a copolymerwith a monomer, oligomer, or polymer having a dihydroxy anthraquinonestructure; for the purpose of improving optical properties, a copolymerwith an oligomer or polymer having an olefin structure, such aspolystyrene; or for the purpose of improving chemical resistance, acopolymer with a polyester resin oligomer or polymer.

Furthermore, in order to improve the appearance and flowability offormed products, the polycarbonate resin may contain a polycarbonateoligomer. The polycarbonate oligomer generally has a viscosity-averagemolecular weight [Mv] of 1500 or more and preferably 2000 or more andgenerally 9500 or less and preferably 9000 or less. In this case, thecontent of the polycarbonate oligomer in the polycarbonate resincomposition according to the first aspect of the present invention ispreferably 30% by mass or less of the polycarbonate resin (including thepolycarbonate oligomer).

The polycarbonate resin may be not only made of virgin raw materials butalso a polycarbonate resin regenerated from used products (so-calledmaterial-recycled polycarbonate resin). Examples of the used productsinclude optical recording media, such as optical disks; light guideplates; vehicle transparent members, such as automobile window glass,automobile headlight lenses, and windshields; containers, such as waterbottles; eyeglass lenses; and architectural members, such as soundbarriers, glass windows, and corrugated sheets. Moreover, for example,nonconforming products, ground products obtained from a sprue, a runner,and the like, and pellets manufactured by melting such products may alsobe used.

The amount of regenerated polycarbonate resin is preferably 80% by massor less and more preferably 50% by mass or less of the polycarbonateresin contained in the polycarbonate resin composition according to thefirst aspect of the present invention. This is because regeneratedpolycarbonate resins are likely to have undergone degradation, such asthermal degradation or aging degradation, and use of such apolycarbonate resin more than the upper limit can cause a deteriorationin hue and mechanical properties.

3. Polycarbosilane Compound

The polycarbonate resin composition according to the first aspect of thepresent invention contains a polycarbosilane compound, that is, asilicon compound having a silicon-carbon bond in the main chain. In thefirst aspect of the present invention, the polycarbosilane compound canimprove surface properties, such as water repellency, oil repellency,anti-fogging properties, anti-fouling properties, stain removability,moisture resistance, lubricity, abrasion resistance, mold releasability,chemical resistance, and scratch resistance, without adversely affectingthe characteristics of the polycarbonate resin composition according tothe first aspect of the present invention. A polycarbonate resincomposition having higher transparency, impact resistance, and heatresistance and causing less outgassing and mold fouling can be producedusing a polycarbosilane compound according to the first aspect of thepresent invention compared with the case where a conventionalorganosiloxane (silicone) compound or polysilane compound is used. Thereason for this is described below.

Conventional organosiloxanes (silicones) are silicon compounds having asilicon-oxygen bond as the main chain. Polysilane compounds are siliconcompounds having a silicon-silicon bond as the main chain. These siliconcompounds therefore have highly inorganic characteristics andconsequently poor compatibility with and dispersibility in polycarbonateresins, which are organic resins. Thus, these silicon compounds tend tocause poor mechanical properties, such as impact resistance, and poortransparency.

In particular, since organosiloxanes generally have low melting points,the blend of the organosiloxanes with polycarbonate resins tends tocause low heat resistance of their resin compositions and increasedoutgassing, which easily causes mold fouling. Use of organosiloxaneshaving lower molecular weights so as to achieve higher transparencyincreases outgassing and mold fouling. Although polysilane compoundstend to be better in terms of heat resistance than organosiloxanecompounds, because of the same reasons as described above, use of thepolysilane compounds results in markedly poor mechanical properties,possibly low transparency, and increased outgassing and mold fouling.

In contrast, polycarbosilane compounds having a silicon-carbon bond inthe main chain contain an organic moiety (organic residue) in the mainchain and have more organic characteristics. Polycarbosilane compoundstherefore have much higher dispersibility in polycarbonate resins thanorganosiloxanes or polysilane compounds and have excellent surfacemodifying effects without causing deterioration in mechanicalproperties, such as impact resistance, and transparency. Furthermore, apolycarbosilane compound according to the first aspect of the presentinvention has high heat resistance, resulting in reduced deteriorationin the heat resistance of a polycarbonate resin composition and markedlyreduced outgassing and mold fouling.

A polycarbosilane compound according to the first aspect of the presentinvention may contain a bond between a silicon atom and an atom otherthan carbon in the main chain without departing from the object of thefirst aspect of the present invention. Examples of such a bond include asilicon-silicon (Si—Si) bond, a silicon-oxygen (Si—O) bond, asilicon-nitrogen (Si—N) bond, a silicon-boron (Si—B) bond, asilicon-phosphorus (Si—P) bond, and a silicon-titanium (Si—Ti) bond.Such a bond may be introduced from components, such as raw materials andcatalysts, or may be unintentionally introduced by oxidation or otheractions during the production of silicon compounds substantially havinga silicon-carbon bond alone.

A polycarbosilane compound used in the first aspect of the presentinvention may have any chemical structure and morphology provided thatthe polycarbosilane compound has two or more repeating units having asilicon-carbon bond (Si—C bond) in the main chain. The polycarbosilanecompound is preferably a silicon compound having a main chain structurein which silicon or a silicon-silicon bond unit and a hydrocarbonresidue are alternately linked to each other, particularly a siliconcompound having a main chain structure containing at least one ofstructural units represented by the following formulae (1) to (3) and ahydrocarbon residue.

In the formulae (1) to (3), R¹, R², and R³ each independently representa monovalent hydrocarbon group, a hydrogen atom, or a silyl group; a, b,and c each independently represent 0 or 1; and a plurality of R¹s, R²s,and R³s in the main chain structure may each be the same or different.

Examples of such a polycarbosilane compound include linear or cyclicpolycarbosilane compounds having a structural unit represented by theformula (1) and a hydrocarbon residue, branched or networkpolycarbosilane compounds having a structural unit represented by theformula (2) or (3) and a hydrocarbon residue, and polycarbosilanecompounds having a combination of structural units represented by theformulae (1) to (3), for example, a combination of the formula (1) andthe formula (2), the formula (1) and the formula (3), the formula (2)and the formula (3), or the formulae (1) to (3), and a hydrocarbonresidue. In particular, linear polycarbosilane compounds having a mainchain structure containing the structural unit represented by theformula (1) and a divalent hydrocarbon residue are preferred becausethey tend to have high dispersibility in polycarbonate resins. Thelinear polycarbosilane compounds may have a branched or networkstructure.

The linear polycarbosilane compounds having a main chain structurecontaining a structural unit represented by the formula (1) and adivalent hydrocarbon residue are preferably those having a repeatingunit represented by the following formula (4):

In the formula (4), R¹, R², a, and b are as defined in the formula (1);A¹ represents a divalent hydrocarbon group having 1 to 12 carbon atoms;p and q each independently represent an integer of 1 to 8; and R¹s, R²s,and A¹s in all the repeating units may each be the same or different.

In the formula (4), p and q each independently represent an integer of 1to 8, preferably 1 to 4, more preferably 1 or 2, and still morepreferably 1.

Such linear polycarbosilane compounds are preferably those having arepeating unit represented by the following formula (5). Such a linearstructure tends to improve the dispersibility in polycarbonate resinsand the transparency and mechanical properties of the polycarbonateresin composition according to the first aspect of the presentinvention.

In the formula (5), R¹ and R² are as defined in the formula (4), A²represents an alkylene group having 1 to 12 carbon atoms, and R¹s, R²s,and A²s in all the repeating units may each be the same or different.

In the formulae (1) to (5), the groups represented by R¹, R², and R³represent at least one selected from a monovalent hydrocarbon group, ahydrogen atom, and a silyl group. Examples of the monovalent hydrocarbongroup include alkyl groups, cycloalkyl groups, alkenyl groups,cycloalkenyl groups, alkynyl groups, aryl groups, and aralkyl groups.Among these, alkyl groups and aryl groups are preferred, alkyl groupsare more preferred, and a methyl group is particularly preferred. Thesubstituents represented by R¹, R², and R³ in all the repeating unitsmay each be the same or different.

Examples of the alkyl groups include a methyl group, an ethyl group, apropyl group, an isopropyl group, a butyl group, a t-butyl group, apentyl group, a hexyl group, an octyl group, a decyl group, and adodecyl group. In general, alkyl groups having 1 to 12 carbon atoms arepreferred. Among these, alkyl groups having 1 to 6 carbon atoms, such asa methyl group, an ethyl group, a propyl group, an isopropyl group, abutyl group, a t-butyl group, a pentyl group, and a hexyl group, arepreferred. A methyl group is particularly preferred.

Examples of the cycloalkyl groups include cycloalkyl groups having 5 to14 carbon atoms, such as a cyclopentyl group and a cyclohexyl group.Among these, cycloalkyl groups having 5 to 8 carbon atoms are preferred.

Examples of the alkenyl groups include alkenyl groups having 2 to 8carbon atoms, such as a vinyl group and an allyl group. Examples of thecycloalkenyl groups include cycloalkenyl groups having 5 to 12 carbonatoms, such as a cyclopentyl group and a cyclohexyl group.

Examples of the alkynyl groups include alkynyl groups having 2 to 8carbon atoms, such as an ethynyl group and a propynyl group, andarylalkynyls, such as an ethynylbenzene group.

Examples of the aryl groups include aryl groups having 6 to 20 carbonatoms, such as a phenyl group, a methylphenyl (or tolyl) group, adimethylphenyl (or xylyl) group, and a naphthyl group. Among these, arylgroups having 6 to 10 carbon atoms are preferred, and a phenyl group isparticularly preferred.

Examples of the aralkyl groups include aralkyl groups having 6 to 20carbon atoms, such as a benzyl group, a phenethyl group, and aphenylpropyl group. Among these, aralkyl groups having 6 to 10 carbonatoms are preferred, and a benzyl group is particularly preferred.

Examples of the silyl groups include silyl groups having 1 to 10 siliconatoms, such as a silyl group, a disilanyl group, and a trisilanyl group.Among these, silyl groups having 1 to 6 silicon atoms are preferred. Inthe case of the silyl group, at least one of the hydrogen atoms may besubstituted with a functional group, such as an alkyl group, an arylgroup, or an alkoxy group.

In the formulae (1) to (5), the substituents represented by R¹, R², andR³ each independently represent more preferably a monovalent hydrocarbongroup or a hydrogen atom, still more preferably an alkyl group or ahydrogen atom, and particularly preferably a methyl group or a hydrogenatom.

In the formulae (1) to (4), a, b, and c represent 0 or 1. The case whereeach of a, b, and c is 0 means that the silicon atoms of thepolycarbosilane compound have an alkyl group, a cycloalkyl group, analkenyl group, a cycloalkenyl group, an alkynyl group, an aryl group, anaralkyl group, or a silyl group as a substituent or are unsubstituted(have hydrogen atoms). The case where each of a, b, and c is 1 meansthat the silicon atoms of the polycarbosilane compound have an alkoxygroup, a cycloalkyloxy group, an alkenyloxy group, a cycloalkenyloxygroup, an alkynyloxy group, an aryloxy group, an aralkyloxy group, or ahydroxyl group as a substituent. Although each of a, b, and c ispreferably 0 in terms of the heat resistance of the polycarbosilanecompound, each of a, b, and c may intentionally be 1 to improve anaffinity for resins or unintentionally be 1 by oxidation or otheractions.

The hydrocarbon residue to be bonded to the structural units representedby the formulae (1) to (3) to form a main chain structure of thepolycarbosilane compound is not particularly limited, may have astraight chain, a branched chain, or a cyclic structure, and may includenot only a saturated bond but also an unsaturated bond. In addition to acarbon atom and a hydrogen atom, the hydrocarbon residue may contain aheteroatom, such as an oxygen atom, a nitrogen atom, a sulfur atom, aphosphorus atom, or a fluorine atom. Among these, divalent totetravalent hydrocarbon groups are preferred, and divalent hydrocarbongroups are particularly preferred.

Specific examples of the divalent hydrocarbon residue to be bonded tothe structural units represented by the formulae (1) to (3) to form themain chain structure of the polycarbosilane compound include thefollowing linear or branched divalent hydrocarbon residues:

alkylene groups having 1 to 12 carbon atoms, such as a methylene group,an ethylene group, a trimethylene group, a propylene group, anisopropylidene group, a tetramethylene group, an isobutylene group, atert-butylene group, an isobutylene group, a pentamethylene group, ahexamethylene group, and an octamethylene group;

alkylidene groups having 2 to 12 carbon atoms, such as an ethylidenegroup, a propylidene group, a butylidene group, a sec-butylidene group,and an isohexylidene group;

cycloalkylene groups having 3 to 12 carbon atoms, such as acyclopentylene group, a cyclohexylene group, a methylcyclohexylenegroup, a trimethylcyclohexylene group, a cycloheptylene group, acyclooctylene group, a cyclononylene group, and a cyclodecylene group;

alkenylene groups having 2 to 12 carbon atoms, such as a vinylene group,a propenylene group, a 1-butenylene group, a 2-butenylene group, a1,3-butadienylene group, a 1-methylpropenylene group, a1-methyl-2-propenylene group, a 1-pentenylene group, a 2-pentenylenegroup, a 1,3-pentadienylene group, a 1,4-pentadienylene group, a1-methylbutenylene group, a 1-methyl-1,2-butadienylene group, a1-hexenylene group, a 2-hexenylene group, a 3-hexenylene group, a1-methylpentenylene group, a 2-methyl-2-pentenylene group, a1,1-dimethyl-2-propenylene group, a 1-ethyl-2-propenylene group, a1,2-dimethylpropenylene group, a 1-methyl-1-butenylene group, a1-heptenylene group, a 1-methylhexenylene group, a 2-methyl-2-hexenylenegroup, a 1,2-dimethylpentenylene group, a 1-octenylene group, a2-octenylene group, a 3-nonenylene group, and a 4-decenylene group;

alkenylidene groups having 2 to 12 carbon atoms, such as a vinylidenegroup, a propynylidene group, and an allylidene group;

cycloalkenylene groups having 3 to 12 carbon atoms, such as a1-cyclopropenylene group, a 2-cyclopentenylene group, a2,4-cyclopentadienylene group, a 1-cyclohexenylene group, a2-cyclohexenylene group, a 1-cycloheptenylene group, a 2-cyclononenylenegroup, a 3-cyclodecenylene group, and a 2-cyclododecenylene group;

alkynylene groups having 2 to 12 carbon atoms, such as an ethynylenegroup, a 1,3-(1-propynylene) group, a 3,3-(1-propynylene) group, a1,4-(1-butynylene) group, a 1,5-(1-pentynylene) group, a1,6-(1-hexynylene) group, and a 1,12-(1-dodecynylene) group;

arylene groups having 6 to 12 carbon atoms, such as an o-phenylenegroup, a m-phenylene group, a p-phenylene group, a methylphenylenegroup, a dimethylphenylene group, a p-xylene-α,α′-diyl group, abiphenylene group, and a naphthylene group; and

aralkylene groups having 6 to 12 carbon atoms, such as —CH₂—C₆H₄—,—CH₂—C₆H₄—CH₂—, —CH₂CH₂—C₆H₄—, —CH₂CH₂—C₆H₄—CH₂—, —CH₂CH₂CH₂—C₆H₄—,—CH(CH₃)CH₂—C₆H₄—, —CH₂CH₂CH₂CH₂—C₆H₄—, and —CH₂CH₂CH(CH₃)—C₆H₄—.

Examples of the trivalent hydrocarbon group to be bonded to thestructural units represented by the formulae (1) to (3) to form the mainchain structure of the polycarbosilane compound include hydrocarbongroups represented by the following formulae (15) and (16).

An example of the tetravalent hydrocarbon group to be bonded to thestructural units represented by the formulae (1) to (3) to form the mainchain structure of the polycarbosilane compound is a hydrocarbon grouprepresented by the following formula (17).

As described above, the hydrocarbon residue is preferably a divalenthydrocarbon group. Among these, an alkylene group, an alkenylene group,an alkynylene group, or an arylene group is preferred, an alkylene groupor an arylene group is particularly preferred, and an alkylene group ismost preferred. The alkylene group is more preferably an alkylene grouphaving 1 to 8 carbon atoms, particularly preferably an alkylene grouphaving 1 to 4 carbon atoms, and most preferably a methylene group.

A¹ in the formula (4) represents a linear or branched divalenthydrocarbon group having 1 to 12 carbon atoms and, more specifically,the divalent hydrocarbon residue described above. A² in the formula (5)represents an alkylene group having 1 to 12 carbon atoms and, morespecifically, the alkylene group having 1 to 12 carbon atoms describedabove. The alkylene groups of A¹ and A² are more preferably alkylenegroups having 1 to 8 carbon atoms, particularly preferably alkylenegroups having 1 to 4 carbon atoms, and most preferably a methylenegroup.

Examples of the polycarbosilane compound used in the first aspect of thepresent invention include those having repeating units described below.However, the polycarbosilane compound is not limited to these examples.The polycarbonate resin composition according to the first aspect of thepresent invention may contain only one polycarbosilane compound or anycombination of two or more polycarbosilane compounds at any ratio.

Among these, polycarbosilane compounds having a repeating unitrepresented by the following formula (6) are particularly preferred.Such polycarbosilane compounds can be easily produced by the thermaldecomposition of polydimethylsilanes with high yields and thus providegreat industrial advantages.

In the exemplary formulae above, n represents the degree ofpolymerization of the polycarbosilane compound and is generally 2 ormore, more preferably 3 or more, particularly preferably 5 or more, andstill more preferably 10 or more and generally 20000 or less, morepreferably 5000 or less, particularly preferably 1000 or less, and stillmore preferably 500 or less. Herein, n not less than the lower limit canresult in reduced outgassing and mold fouling in the polycarbonate resincomposition according to the first aspect of the present invention andis therefore preferred. On the other hand, n not more than the upperlimit results in improved dispersibility in the polycarbonate resinaccording to the first aspect of the present invention and tends toresult in improved mechanical properties of the polycarbonate resincomposition according to the first aspect of the present invention.

The molecular weight of the polycarbosilane compound according to thefirst aspect of the present invention is not particularly limited andmay be appropriately determined. The number-average molecular weight[Mn] of the polycarbosilane compound is generally 100 or more,preferably 200 or more, more preferably 300 or more, and particularlypreferably 500 or more and generally 20000 or less, preferably 10000 orless, more preferably 5000 or less, and particularly preferably 3000 orless. The number-average molecular weight not less than the lower limitcan result in reduced outgassing and mold fouling in the polycarbonateresin composition according to the first aspect of the present inventionand is therefore preferred. The number-average molecular weight not morethan the upper limit results in the suppression of reduction in theflowability of the polycarbonate resin composition according to thefirst aspect of the present invention, improving shaping processabilityand facilitating shape processing. The number-average molecular weightnot more than the upper limit also tends to result in improvedmechanical properties. Two or more polycarbosilane compounds havingdifferent number-average molecular weights may be used in combination.In this case, polycarbosilane compounds having number-average molecularweights outside the suitable range described above may be mixed.

The number-average molecular weight [Mn], as used herein, is a valuemeasured by gel permeation chromatography (GPC) (apparatus: Tosho 8020,column: Tosoh TSKgel Multipore Hxl-M) at a temperature of 40° C. usingtetrahydrofuran as a solvent.

The melting point of the polycarbosilane compound according to the firstaspect of the present invention is not particularly limited and may beappropriately determined. The melting point of the polycarbosilanecompound is generally 20° C. or more, preferably 30° C. or more, morepreferably 40° C. or more, and particularly preferably 60° C. or moreand generally 500° C. or less, preferably 300° C. or less, morepreferably 280° C. or less, and particularly preferably 260° C. or less.The melting point not less than the lower limit can result in reducedmold fouling in the polycarbonate resin composition according to thefirst aspect of the present invention and is therefore preferred. Themelting point not more than the upper limit results in improveddispersibility in the polycarbonate resin according to the first aspectof the present invention and tends to result in improved mechanicalproperties of the polycarbonate resin composition according to the firstaspect of the present invention. Two or more polycarbosilane compoundshaving different melting points may be used in combination. In thiscase, polycarbosilane compounds having melting points outside thesuitable range described above may be mixed.

A method for producing a polycarbosilane compound according to the firstaspect of the present invention is not particularly limited and may beappropriately determined. Among others, a direct synthesis method and athermal decomposition method are exemplified.

An example of the direct synthesis method is a method in which at leastone dihalogen silane and at least one dihalogen hydrocarbon areco-condensed in the presence of a catalyst, such as an alkali metal. Inthis case, the reaction is generally performed in a suspension of acatalyst, such as an alkali metal, using a solvent. Examples of thesolvent for use in the suspension preferably include hydrocarbonsolvents, more preferably toluene, xylene, and decalin. After othercomponents (dihalogen silane and dihalogen hydrocarbon) are introducedin the catalyst suspension and the reaction is performed, an objectiveproduct can be obtained from the reaction mixture by an appropriatemethod. When the polycarbosilane compound is, for example, soluble inthe solvent, other insoluble components may be removed by filtration.The polycarbosilane compound remaining in the solvent can be cleaned bywashing with water and can be dried into a powder by removing thesolvent. When the synthesized polycarbosilane compound is insoluble inthe solvent, the polycarbosilane compound can be extracted with anappropriate solvent. Subsequently, the polycarbosilane compound can becleaned by washing with water and can be dried into a powder by removingthe solvent.

An example of the thermal decomposition method is a method in which apolycarbosilane compound is produced by pyrolytic conversion by heatingan alkylsilane, such as tetramethylsilane, or a polysilane, such aspolydimethylsilane (polymethylsilylene), at high temperature. Theheating temperature generally ranges from 350° C. to 1000° C. and morepreferably 400° C. to 800° C. Although the reaction may be performedunder atmospheric pressure or high pressure, high pressure is preferredbecause the yield tends to increase. The addition of a catalytic amountof a boron compound, such as polyborodiphenylsiloxane, is alsopreferred. The amount of boron compound to be added is generally 0.1parts by mass or more, preferably 0.2 parts by mass or more, and morepreferably 0.5 parts by mass or more and generally 5 parts by mass orless, preferably 3 parts by mass or less, and more preferably 2 parts bymass or less relative to 100 parts by mass of the alkylsilane orpolysilane. The boron compound content not less than the lower limittends to result in an increased yield of the polycarbosilane compoundaccording to the first aspect of the present invention. The boroncompound content not more than the upper limit can result in a reducedoxygen content of the polycarbosilane compound according to the firstaspect of the present invention and the suppression of reduction in heatresistance and dispersibility in polycarbonate resins.

Among these, a method for producing a polycarbosilane compound from thepolysilane compound by the thermal decomposition method is preferred interms of quality and cost as a method for producing a polycarbosilanecompound according to the first aspect of the present invention. Two ormore polycarbosilane compounds produced by different methods may be usedin combination. In this case, polycarbosilane compounds produced bymethods outside the suitable method described above may be mixed.

The content of the polycarbosilane compound in the polycarbonate resincomposition according to the first aspect of the present invention ispreferably 0.001 parts by mass or more, 0.005 parts by mass or more,more preferably 0.01 parts by mass or more, still more preferably 0.02parts by mass or more, particularly preferably 0.05 parts by mass ormore, and most preferably 0.1 parts by mass or more and preferably 20parts by mass or less, more preferably 15 parts by mass or less, stillmore preferably 10 parts by mass or less, and particularly preferably7.5 parts by mass or less relative to 100 parts by mass of thepolycarbonate resin. An excessively low content of polycarbosilanecompound can result in insufficient effects of modifying surfaceproperties, such as water repellency, oil repellency, anti-foggingproperties, anti-fouling properties, stain removability, moistureresistance, lubricity, abrasion resistance, mold releasability, chemicalresistance, and scratch resistance. On the other hand, at an excessivelyhigh content of polycarbosilane compound, its effects may be leveled offand thus its use may be uneconomical, and also the polycarbonate resincomposition may have low mechanical strength.

The polycarbosilane compound according to the first aspect of thepresent invention may be used alone or in combination.

4. Other Components

The polycarbonate resin composition according to the first aspect of thepresent invention may optionally contain components other than thosedescribed above provided that desired physical properties are notdeteriorated significantly. Examples of the other components includeresins other than polycarbonate resins and various resin additiveagents. The other components may be contained alone, or two or more ofthe other components may be contained at any ratio.

<Other Resins>

Examples of other resins that can be blended together with apolycarbonate resin in the polycarbonate resin composition according tothe first aspect of the present invention include:

thermoplastic polyester resins, such as a polyethylene terephthalateresin (PET resin), polytrimethylene terephthalate (PTT resin), apolybutylene terephthalate resin (PBT resin), polylactic acid (PLA), apolybutylene succinate resin (PBS), and polycaprolactone (PCL);

styrene resins, such as a polystyrene resin (PS resin), a high-impactpolystyrene resin (HIPS), an acrylonitrile-styrene copolymer (AS resin),an acrylonitrile-butadiene-styrene copolymer (ABS resin), anacrylonitrile-styrene-acrylic rubber copolymer (ASA resin), and anacrylonitrile-ethylene propylene rubber-styrene copolymer (AES resin);

polyolefin resins, such as a polyethylene resin (PE resin), apolypropylene resin (PP resin), a cyclic cycloolefin resin (COP resin),and a cyclic cycloolefin copolymer resin (COC resin);

polyamide resins (PA resins); polyimide resins (PI resins);polyetherimide resins (PEI resins); polyurethane resins (PU resins);polyphenylene ether resins (PPE resins); polyphenylene sulfide resins(PPS resins); polysulfone resins (PSU resins); and polymethylmethacrylate resins (PMMA resins).

The other resins may be contained alone, or two or more of the otherresins may be contained at any ratio.

<Resin Additive Agents>

Examples of the resin additive agents include a flame retardant, a heatstabilizer, an antioxidant, a mold-release agent, an ultravioletabsorber, a dye or pigment, a flame retardant, an anti-dripping agent,an antistatic agent, an anti-fogging agent, a lubricant, ananti-blocking agent, a flow modifier, a sliding modifier, a plasticizer,a dispersant, and an antimicrobial agent. The resin additive agents maybe contained alone, or two or more of the resin additive agents may becontained at any ratio.

Examples of the resin additive agents suitable for the polycarbonateresin composition according to the first aspect of the present inventionwill be more specifically described below.

[Flame Retardant]

Examples of the flame retardant include metal salt compounds, halides,and phosphorus compounds. Metal salt compounds can be suitably used.

The description of [3. Metal Salt Compound] in II. Second Aspect of thePresent Invention described below can be applied to the metal saltcompounds.

The content of metal salt compound serving as a flame retardant in thepolycarbonate resin composition according to the first aspect of thepresent invention is preferably 0.01 parts by mass or more, morepreferably 0.02 parts by mass or more, still more preferably 0.03 partsby mass or more, and particularly preferably 0.05 parts by mass or moreand preferably 1 part by mass or less, more preferably 0.75 parts bymass or less, still more preferably 0.5 parts by mass or less, andparticularly preferably 0.3 parts by mass or less relative to 100 partsby mass of the polycarbonate resin. An excessively low content of metalsalt compound has insufficient effects of improving the flame resistanceof the polycarbonate resin composition. On the other hand, anexcessively high content of metal salt compound may result in reducedthermal stability of the polycarbonate resin composition and poorappearance and low mechanical strength of a formed product.

[Heat Stabilizer]

Examples of the heat stabilizer include phosphorus compounds.

Phosphorus compounds may be any known phosphorus compounds. Specificexamples of the phosphorus compounds include phosphorus oxo acids, suchas phosphoric acid, phosphonic acid, phosphorous acid, phosphinic acid,and polyphosphoric acid; acid pyrophosphate metal salts, such as sodiumacid pyrophosphate, potassium acid pyrophosphate, and calcium acidpyrophosphate; phosphates of periodic table group 1 or 2B metal, such aspotassium phosphate, sodium phosphate, cesium phosphate, and zincphosphate; and organic phosphate compounds, organic phosphite compounds,and organic phosphonite compounds.

Among these, organic phosphite compounds represented by the followingformulae (18) to (20), organic phosphonite compounds represented by thefollowing formula (21), and organic phosphate compounds represented bythe following formula (22) are preferred.

In the formulae (18) to (22), R¹⁸, R¹⁹, R²⁰, R²¹, R²², R²³, R²⁴, R²⁵,R²⁶, R²⁷, and R²⁸ represent an alkyl group or an aryl group. Amongthese, R¹⁸, R¹⁹, R²⁰, R²¹, R²², R²³, R²⁴, R²⁵, R²⁶, R²⁷, and R²⁸ morepreferably represent an alkyl group generally having 1 or more,preferably 2 or more, and generally 30 or less, preferably 25 or less,carbon atoms, or an aryl group generally having 6 or more and 30 or lesscarbon atoms. R¹⁸, R¹⁹, R²⁰, R²², and R²³ preferably represent an arylgroup rather than an alkyl group. R²¹, R²⁴, R²⁵, R²⁶, R²⁷, and R²⁸preferably represent an alkyl group rather than an aryl group. R¹⁸, R¹⁹,R²⁰, R²¹, R²², R²³, R²⁴, R²⁵, R²⁶, R²⁷, and R²⁸ may be the same ordifferent.

In the formulae (19) and (21), X⁶ and X⁷ represent an aryl residuehaving 6 to 30 carbon atoms. In the formula (22), d generally representsan integer of 0 or more and preferably 1 or more and generally 2 orless.

Examples of the organic phosphite compounds represented by the formula(18) include triphenyl phosphite, tris(monononylphenyl)phosphite,tris(monononyl/dinonyl.phenyl)phosphite,tris(2,4-di-tert-butylphenyl)phosphite, monooctyldiphenyl phosphite,dioctylmonophenyl phosphite, monodecyldiphenyl phosphite,didecylmonophenyl phosphite, tridecyl phosphite, trilauryl phosphite,and tristearyl phosphite. Specific examples of the organic phosphitecompounds include “ADK STAB 1178” and “ADK STAB 2112” manufactured byAdeka Corp., “JP-351”, “JP-360”, and “JP-3CP” manufactured by JohokuChemical Co., Ltd., and “Irgafos 168” manufactured by Ciba SpecialtyChemicals Co., Ltd.

An example of the organic phosphite compounds represented by the formula(19) is 2,2-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite. Aspecific example of the organic phosphite compounds is “ADK STAB HP-10”manufactured by Adeka Corp.

Examples of the organic phosphite compounds represented by the formula(20) include distearyl pentaerythritol diphosphite,bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, andbis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite.Specific examples of the organic phosphite compounds include “ADK STABPEP-8”, “ADK STAB PEP-24G”, and “ADK STAB PEP-36” manufactured by AdekaCorp. and “JPP-2000” manufactured by Johoku Chemical Co., Ltd.

An example of the organic phosphonite compounds represented by theformula (21) istetrakis(2,4-di-tert-butylphenyl)-4,4′-biphenylene-di-phosphonite. Aspecific example of the organic phosphonite compounds is “SandostabP-EPQ” manufactured by Sandoz.

Examples of the organic phosphate compounds represented by the formula(22) include mono-stearic acid phosphate, di-stearic acid phosphate,mono-2-ethylhexyl acid phosphate, di-2-ethylhexyl acid phosphate,monooleyl acid phosphate, and di-oleyl acid phosphate. Specific examplesof the organic phosphate compounds include “ADK STAB AX-71” manufacturedby Adeka Corp. and “JP-508” and “JP-518-O” manufactured by JohokuChemical Co., Ltd.

The heat stabilizers may be contained alone, or two or more of the heatstabilizers may be contained at any ratio.

The content of the heat stabilizer in the polycarbonate resincomposition according to the first aspect of the present invention isgenerally 0.001 parts by mass or more, preferably 0.01 parts by mass ormore, and more preferably 0.03 parts by mass or more and generally 1part by mass or less, preferably 0.7 parts by mass or less, and morepreferably 0.5 parts by mass or less relative to 100 parts by mass ofthe polycarbonate resin. A heat stabilizer content less than or equal tothe lower limit may result in an insufficient heat stabilizing effect.At a heat stabilizer content more than the upper limit, its effect maybe leveled off and thus its use may be uneconomical.

[Antioxidant]

An example of the antioxidant is a hindered phenol antioxidant. Specificexamples of the antioxidant include pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],N,N′-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide),2,4-dimethyl-6-(1-methylpentadecyl)phenol,diethyl[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]phosphoate,3,3′,3″,5,5′,5″-hexa-tert-butyl-a,a′,a″-(mesitylene-2,4,6-triyl)tri-p-cresol,4,6-bis(octylthiomethyl)-o-cresol,ethylenebis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)propionate],hexamethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trion,and2,6-di-tert-butyl-4-(4,6-bis(octylthio)-1,3,5-triazine-2-ylamino)phenol.

Among these, pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] andoctadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate are preferred.Specific examples of the phenol antioxidant include “Irganox 1010” and“Irganox 1076” manufactured by Ciba Specialty Chemicals Co., Ltd. and“ADK STAB AO-50” and “ADK STAB AO-60” manufactured by Adeka Corp.

The antioxidants may be contained alone, or two or more of theantioxidants may be contained at any ratio.

The content of the antioxidant in the polycarbonate resin compositionaccording to the first aspect of the present invention is generally0.001 parts by mass or more and preferably 0.01 parts by mass or moreand generally 1 part by mass or less and preferably 0.5 parts by mass orless relative to 100 parts by mass of the polycarbonate resin. Anantioxidant content less than or equal to the lower limit may result inan insufficient antioxidant effect. At an antioxidant content more thanthe upper limit, its effect may be leveled off and thus its use may beuneconomical.

[Mold-Release Agent]

Examples of the mold-release agent include aliphatic carboxylic acids,esters of aliphatic carboxylic acids and alcohols, aliphatic hydrocarboncompounds having a number-average molecular weight of 200 to 15000, andpolysiloxane silicone oils.

Examples of the aliphatic carboxylic acids include saturated andunsaturated aliphatic monovalent, divalent, and trivalent carboxylicacids. The aliphatic carboxylic acids include alicyclic carboxylicacids. Among these, preferred aliphatic carboxylic acids are monovalentand divalent carboxylic acids having 6 to 36 carbon atoms. Aliphaticsaturated monovalent carboxylic acids having 6 to 36 carbon atoms aremore preferred. Examples of the aliphatic carboxylic acids includepalmitic acid, stearic acid, caproic acid, capric acid, lauric acid,arachidic acid, behenic acid, lignoceric acid, cerotic acid, melissicacid, tetrariacontanoic acid, montanic acid, adipic acid, and azelaicacid.

Examples of the aliphatic carboxylic acids in the esters of aliphaticcarboxylic acids and alcohols include the aliphatic carboxylic acidsdescribed above. Examples of the alcohols include saturated andunsaturated monohydric and polyhydric alcohols. These alcohols may havea substituent, such as a fluorine atom or an aryl group. Among these,saturated monohydric and polyhydric alcohols having 30 or less carbonatoms are preferred, and aliphatic saturated monohydric alcohols andaliphatic saturated polyhydric alcohols each having 30 or less carbonatoms are more preferred. The aliphatics, as used herein, includealicyclic compounds.

Specific examples of the alcohols include octanol, decanol, dodecanol,stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol,glycerin, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentyleneglycol, ditrimethylolpropane, and dipentaerythritol.

The esters may contain an aliphatic carboxylic acid and/or an alcohol asan impurity. The esters may be pure substances or mixtures of aplurality of compounds. The aliphatic carboxylic acids and the alcoholsto constitute the esters may be used alone or in any combination at anyratio.

The esters of aliphatic carboxylic acids and alcohols are classifiedinto full esters in which all the carboxyl groups of the aliphaticcarboxylic acid are esterified and partial esters in which the carboxylgroups are partly esterified. The esters of aliphatic carboxylic acidsand alcohols used in the first aspect of the present invention may befull esters or partial esters.

Specific examples of the esters of aliphatic carboxylic acids andalcohols include beeswax (a mixture mainly composed of myricylpalmitate), stearyl stearate, behenyl behenate, stearyl behenate,glycerin monopalmitate, glycerin monostearate, glycerin distearate,glycerin tristearate, pentaerythritol monopalmitate, pentaerythritolmonostearate, pentaerythritol distearate, pentaerythritol tristearate,and pentaerythritol tetrastearate.

Examples of the aliphatic hydrocarbons having a number-average molecularweight of 200 to 15000 include liquid paraffin, paraffin wax,microcrystalline wax, polyethylene wax, Fischer-Tropsch wax, andα-olefin oligomers having 3 to 12 carbon atoms. The aliphatichydrocarbons include alicyclic hydrocarbons. These hydrocarbons may bepartially oxidized.

Among these, paraffin wax, polyethylene wax, and partially oxidizedpolyethylene wax are preferred, and paraffin wax and polyethylene waxare more preferred.

The aliphatic hydrocarbons preferably have a number-average molecularweight of 5000 or less.

Each of the aliphatic hydrocarbons may be a single substance or amixture of substances having different compositions and molecularweights provided that the main component is within the range describedabove.

Examples of the polysiloxane silicone oils include dimethyl siliconeoil, methylphenyl silicone oil, diphenyl silicone oil, and fluorinatedalkyl silicone.

The mold-release agents may be contained alone, or two or more of themold-release agents may be contained at any ratio.

The content of the mold-release agent in the polycarbonate resincomposition according to the first aspect of the present invention isgenerally 0.001 parts by mass or more and preferably 0.01 parts by massor more and generally 2 parts by mass or less and preferably 1 part bymass or less relative to 100 parts by mass of the polycarbonate resin. Amold-release agent content less than or equal to the lower limit mayresult in insufficient mold releasability. A mold-release agent contentmore than the upper limit may result in low hydrolysis resistance andmold fouling during injection molding.

[Ultraviolet Absorber]

Examples of the ultraviolet absorber include inorganic ultravioletabsorbers, such as cerium oxide and zinc oxide; and organic ultravioletabsorbers, such as benzotriazole compounds, benzophenone compounds,salicylate compounds, cyanoacrylate compounds, triazine compounds,oxanilide compounds, malonate compounds, and hindered amine compounds.Among these, the organic ultraviolet absorbers are preferred, andbenzotriazole compounds are more preferred. The organic ultravioletabsorbers can be used to improve the transparency and mechanicalproperties of the polycarbonate resin composition according to the firstaspect of the present invention.

Specific examples of the benzotriazole compounds include2-(2′-hydroxy-5′-methylphenyl)benzotriazole,2-[2′-hydroxy-3′,5′-bis(α,α-dimethylbenzyl)phenyl]-benzotriazole,2-(2′-hydroxy-3′,5′-di-tert-butyl-phenyl)-benzotriazole,2-(2′-hydroxy-3′-tert-butyl-5′-methylphenyl)-5-chlorobenzotriazole,2-(2′-hydroxy-3′,5′-di-tert-butylphenyl)-5-chlorobenzotriazole),2-(2′-hydroxy-3′,5′-di-tert-amyl)-benzotriazole,2-(2′-hydroxy-5′-tert-octylphenyl)benzotriazole, and2,2′-methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazol-2-yl)phenol].Among these, 2-(2′-hydroxy-5′-tert-octylphenyl)benzotriazole and2,2′-methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazol-2-yl)phenol]are preferred, and 2-(2′-hydroxy-5′-tert-octylphenyl)benzotriazole isparticularly preferred.

Examples of commercially available benzotriazole compounds include“Seesorb 701”, “Seesorb 705”, “Seesorb 703”, “Seesorb 702”, “Seesorb704”, and “Seesorb 709” manufactured by Shipro Kasei Kaisha Ltd.,“Viosorb 520”, “Viosorb 582”, “Viosorb 580”, and “Viosorb 583”manufactured by Kyodo Chemical Co., Ltd., “Kemisorb 71” and “Kemisorb72” manufactured by Chemipro Kasei Kaisha, Ltd., “Cyasorb UV5411”manufactured by Cytec Industries Inc., “LA-32”, “LA-38”, “LA-36”,“LA-34”, and “LA-31” manufactured by Adeka Corp., and “Tinuvin P”,“Tinuvin 234”, “Tinuvin 326”, “Tinuvin 327”, and “Tinuvin 328”manufactured by Ciba Specialty Chemicals Co., Ltd.

Specific examples of the benzophenone compounds include2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone,2-hydroxy-4-methoxybenzophenone-5-sulfonic acid,2-hydroxy-4-n-octoxybenzophenone, 2-hydroxy-n-dodesiloxybenzophenone,bis(5-benzoyl-4-hydroxy-2-methoxyphenyl)methane,2,2′-dihydroxy-4-methoxybenzophenone, and2,2′-dihydroxy-4,4′-dimethoxybenzophenone.

Examples of commercially available benzophenone compounds include“Seesorb 100”, “Seesorb 101”, “Seesorb 101S”, “Seesorb 102”, “Seesorb103” manufactured by Shipro Kasei Kaisha Ltd., “Viosorb 100”, “Viosorb110”, and “Viosorb 130” manufactured by Kyodo Chemical Co., Ltd.,“Kemisorb 10”, “Kemisorb 11”, “Kemisorb 11S”, “Kemisorb 12”, “Kemisorb13”, and “Kemisorb 111” manufactured by Chemipro Kasei Kaisha, Ltd.,“Uvinul 400” manufactured by BASF, “Uvinul M-40” manufactured by BASF,“Uvinul MS-40” manufactured by BASF, “Cyasorb UV9”, “Cyasorb UV284”,“Cyasorb UV531”, and “Cyasorb UV24” manufactured by Cytec IndustriesInc., and “ADK STAB 1413” and “ADK STAB LA-51” manufactured by AdekaCorp.

Specific examples of salicylate compounds include phenyl salicylate and4-tert-butylphenyl salicylate. Examples of commercially availablesalicylate compounds include “Seesorb 201” and “Seesorb 202”manufactured by Shipro Kasei Kaisha Ltd. and “Kemisorb 21” and “Kemisorb22” manufactured by Chemipro Kasei Kaisha, Ltd.

Specific examples of cyanoacrylate compounds includeethyl-2-cyano-3,3-diphenyl acrylate and2-ethylhexyl-2-cyano-3,3-diphenyl acrylate. Examples of commerciallyavailable cyanoacrylate compounds include “Seesorb 501” manufactured byShipro Kasei Kaisha Ltd., “Viosorb 910” manufactured by Kyodo ChemicalCo., Ltd., “Uvisolator 300” manufactured by Daiichi Kasei Co., Ltd., and“Uvinul N-35” and “Uvinul N-539” manufactured by BASF.

A specific example of the oxanilide compounds is2-ethoxy-2′-ethyloxanilic acid bisanilide. An example of thecommercially available oxanilide compounds include “Sanduvor VSU”manufactured by Clariant AG.

The malonate compounds are preferably 2-(alkylidene) malonates and morepreferably 2-(1-arylalkylidene) malonates. Examples of commerciallyavailable malonate compounds include “PR-25” manufactured by Clariant(Japan) K.K. and “B-CAP” manufactured by Ciba Specialty Chemicals Co.,Ltd.

The content of the ultraviolet absorber in the polycarbonate resincomposition according to the first aspect of the present invention isgenerally 0.01 parts by mass or more and preferably 0.1 parts by mass ormore and generally 3 parts by mass or less and preferably 1 part by massor less relative to 100 parts by mass of the polycarbonate resin. Anultraviolet absorber content less than or equal to the lower limit mayresult in an insufficient effect of improving weatherability. Anultraviolet absorber content more than the upper limit results in theoccurrence of mold deposit or the like, possibly causing mold fouling.The ultraviolet absorbers may be contained alone, or two or more of theultraviolet absorbers may be contained at any ratio.

[Dye or Pigment]

Examples of the dye or pigment include inorganic pigments, organicpigments, and organic dyes.

Examples of the inorganic pigments include carbon black; sulfidepigments, such as cadmium red and cadmium yellow; silicate pigments,such as ultramarine blue; oxide pigments, such as titanium oxide, zincwhite, red iron oxide, chromium oxide, iron black, titan yellow,zinc-iron brown, titanium cobalt green, cobalt green, cobalt blue,copper-chromium black, and copper-iron black; chromate pigments, such aschrome yellow and molybdate orange; and ferrocyanide pigments, such asiron blue.

Examples of the organic pigments and organic dyes include phthalocyaninedyes and pigments, such as copper phthalocyanine blue and copperphthalocyanine green; azo dyes and pigments, such as nickel azo yellow;thioindigo-based, perinone-based, perylene-based, quinoline-based,quinacridone-based, dioxazine-based, isoindolinone-based, andquinophthalone-based condensed polycyclic dyes and pigments;anthraquinone-based, heterocycle-based, and methyl-based dyes andpigments.

Among these, in terms of thermal stability, titanium oxide, carbonblack, and cyanine-based, quinoline-based, anthraquinone-based, andphthalocyanine-based compounds are preferred.

The dyes and pigments may be contained alone, or two or more of the dyesand pigments may be contained at any ratio. The dye or pigment may becontained in a masterbatch together with a polystyrene resin, apolycarbonate resin, or an acrylic resin to improve handleability duringextrusion and dispersibility in resin compositions.

The content of the dye or pigment in the polycarbonate resin compositionaccording to the first aspect of the present invention is generally 5parts by mass or less, preferably 3 parts by mass or less, and morepreferably 2 parts by mass or less relative to 100 parts by mass of thepolycarbonate resin. An excessively high content of dye or pigment mayresult in insufficient impact resistance.

[Anti-Dripping Agent]

Examples of the anti-dripping agent include fluoropolymers. Among these,fluoroolefin resins are preferred.

The description of [3. Fluoropolymer] in III. Third Aspect of thePresent Invention described below can be applied to the fluoropolymersserving as anti-dripping agents.

The anti-dripping agents may be contained alone, or two or more of theanti-dripping agents may be contained at any ratio.

The content of the anti-dripping agent in the polycarbonate resincomposition according to the first aspect of the present invention isgenerally 0.001 parts by mass or more, preferably 0.005 parts by mass ormore, more preferably 0.01 parts by mass or more, and particularlypreferably 0.02 parts by mass or more and generally 1 part by mass orless, preferably 0.5 parts by mass or less, more preferably 0.3 parts bymass or less, and particularly preferably 0.1 parts by mass or lessrelative to 100 parts by mass of the polycarbonate resin. Ananti-dripping agent content less than or equal to the lower limit mayresult in insufficient effects on flame resistance produced by theanti-dripping agent. An anti-dripping agent content more than the upperlimit may result in poor appearance, low mechanical strength, orsignificantly low transparency of formed products obtained by shapingthe polycarbonate resin composition.

5. Method for Producing Polycarbonate Resin Composition

A method for producing the polycarbonate resin composition according tothe first aspect of the present invention is not particularly limited.Various known methods for producing polycarbonate resin compositions canbe employed.

A specific example is a method in which a polycarbonate resin, apolycarbosilane compound, and other components to be optionally blendedare mixed in advance, for example, in a mixer, such as a tumbler or aHenschel mixer, and are melt-kneaded in a mixer, such as a Banburymixer, a roll, a Brabender, a single-screw extruder, a twin-screwextruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and then melt-kneaded to producethe polycarbonate resin composition according to the first aspect of thepresent invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and melt-kneaded to produce the polycarbonate resincomposition according to the first aspect of the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

6. Polycarbonate Resin Formed Product

The polycarbonate resin composition according to the first aspect of thepresent invention can generally be formed into polycarbonate resinformed products having any shape. The shape, design, color, and size ofthe formed products are not particularly limited and may beappropriately determined in accordance with each application of theformed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators. Among these, the formed products aresuitably used for components of electrical and electronic devices, OAequipment, information terminals, household electrical appliances, andilluminators and are particularly suitably used for components ofelectrical and electronic devices.

Examples of the electrical and electronic devices include personalcomputers, game machines, display units, such as television sets,printers, copying machines, scanners, facsimiles, electronic notebooksand PDAs, electronic calculators, electronic dictionaries, cameras,video cameras, cellular phones, battery packs, recording medium drivesand readers, mouses, numeric keypads, CD players, MD players, andportable radios and audio-players.

A method for manufacturing formed products is not particularly limited.Any common molding method for polycarbonate resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies, afoam molding (including supercritical fluid) method, an insert moldingmethod, an IMC (in-mold coating molding) molding method, an extrusionmolding method, a sheet forming method, a thermoforming method, arotational molding method, a laminate molding method, and a pressforming method. A hot-runner molding method may also be used.

The polycarbonate resin formed product according to the first aspect ofthe present invention obtained by shaping the polycarbonate resincomposition according to the first aspect of the present invention hassurface properties, such as water repellency, oil repellency,anti-fogging properties, anti-fouling properties, stain removability,moisture resistance, lubricity, abrasion resistance, mold releasability,chemical resistance, and scratch resistance, modified without adverselyaffecting the excellent intrinsic characteristics of polycarbonateresins. Thus, the polycarbonate resin formed product can be used as apractical formed product in a wide variety of applications.

7. Modifier for Polycarbonate Resin

The modifier for polycarbonate resins according to the first aspect ofthe present invention contains the polycarbosilane compound according tothe first aspect of the present invention, preferably having a mainchain structure containing at least one of structural units representedby the formulae (1) to (3) and a hydrocarbon residue, wherein thehydrocarbon residue is a divalent hydrocarbon group. More preferably,the modifier for polycarbonate resins contains a polycarbosilanecompound having a repeating unit represented by the formula (4),particularly the formula (5), and more particularly the formula (6) anda number-average molecular weight of 100 to 20000. The modifier forpolycarbonate resins is industrially quite useful in improving thesurface properties of the polycarbonate resin composition, such as waterrepellency, oil repellency, anti-fogging properties, anti-foulingproperties, stain removability, moisture resistance, lubricity, abrasionresistance, mold releasability, chemical resistance, and scratchresistance, without adversely affecting the intrinsic characteristics ofpolycarbonate resins, such as transparency, heat resistance, andmechanical properties, e.g., impact resistance.

II. Second Aspect of the Present Invention 1. Overview

A polycarbonate resin composition according to a second aspect of thepresent invention contains at least a polycarbonate resin, a metal saltcompound, and a polycarbosilane compound. The polycarbonate resincomposition according to the second aspect of the present invention mayoptionally contain other components.

Polycarbosilane compounds are compounds having two or more repeatingunits each having a silicon-carbon bond (Si—C bond) in their mainchains. The polycarbosilane compound used in the second aspect of thepresent invention has the Si—C bond in its main chain and thus hasexcellent dispersibility in and compatibility with polycarbonate resins.Consequently, there can be solved the problems of existing polycarbonateresin compositions containing an organosiloxane (silicone) compound or apolysilane compound, such as degradations of transparency, impactresistance, and heat resistance, and outgassing and mold fouling.

2. Polycarbonate Resin

There is no limitation on the type of polycarbonate resin used in thepolycarbonate resin composition according to the second aspect of thepresent invention.

Polycarbonate resins may be used alone, or two or more polycarbonateresins may be combined with each other at any ratio.

Among these, the polycarbonate resin preferably contains a predeterminedpercentage of a polycarbonate resin having a structural viscosity indexN within a predetermined range.

The polycarbonate resin in the second aspect of the present invention isa polymer having a basic structure having a carbonate bond representedby the following formula (7).

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins may be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

In the second aspect of the present invention, the above descriptions of[2-1. Dihydroxy Compound], [2-2. Carbonate Precursor], and [2-3. Methodfor Producing Polycarbonate Resin] in I. First Aspect of the PresentInvention can be applied to [2-1. Dihydroxy Compound], [2-2. CarbonatePrecursor], and [2-3. Method for Producing Polycarbonate Resin] of thepolycarbonate resin, respectively.

The polycarbonate resin used in the second aspect of the presentinvention is preferably produced by the melt transesterification methoddescribed above, because such polycarbonate resins can be produced withrelatively inexpensive and industrially available raw materials.

[2-4. Structural Viscosity Index of Polycarbonate Resin]

The polycarbonate resin in the second aspect of the present inventionpreferably contains at least a certain percentage of a polycarbonateresin having a structural viscosity index N within a predeterminedrange.

The structural viscosity index N is an index for evaluating therheological characteristics of a molten substance. In general, the meltproperty of a polycarbonate resin can be expressed by the numericalformula: γ=a·σ^(N), wherein γ represents the shear rate, a represents aconstant, σ represents the stress, and N represents the structuralviscosity index.

In this numerical formula, N=1 indicates Newtonian flow, and an increasein N results in an increase in non-Newtonian flow. Thus, the rheologicalcharacteristics of a molten substance can be evaluated by the structuralviscosity index N. In general, polycarbonate resins having a highstructural viscosity index N tend to have a high melt viscosity in alow-shear region. Thus, a polycarbonate resin having a high structuralviscosity index N can be mixed with another polycarbonate resin tosuppress the dripping of the resulting polycarbonate resin compositionduring combustion, thereby improving flame resistance. In order tomaintain high formability of the resulting polycarbonate resincomposition, however, it is preferable that the structural viscosityindex N of the polycarbonate resin is not excessively high.

Thus, the polycarbonate resin in the polycarbonate resin compositionaccording to the second aspect of the present invention preferablycontains at least a certain percentage of a polycarbonate resin,preferably an aromatic polycarbonate resin, having a structuralviscosity index N of generally 1.2 or more, preferably 1.25 or more, andmore preferably 1.28 or more and generally 1.8 or less and preferably1.7 or less. A polycarbonate resin, particularly an aromaticpolycarbonate resin, having a high structural viscosity index N cansuppress the dripping of the polycarbonate resin composition accordingto the second aspect of the present invention during combustion, therebyimproving flame resistance.

As described in, for example, Japanese Unexamined Patent ApplicationPublication No. 2005-232442, the “structural viscosity index N” can alsobe expressed by Log η_(a)=[(1−N)/N]×Log γ+C, from which the equationdescribed above has been derived. In this equation, N represents thestructural viscosity index, γ represents the shear rate, C represents aconstant, and η_(a) represents the apparent viscosity. As shown by thisequation, the N value can also be determined from γ values and η_(a)values in low-shear regions that are greatly different in viscositybehavior. For example, the N value can be determined from η_(a) valuesat γ=12.16 sec⁻¹ and γ=24.32 sec⁻¹.

In the polycarbonate resin composition according to the second aspect ofthe present invention, it is desirable that the polycarbonate resincontain generally 20% by mass or more, preferably 50% by mass or more,and more preferably 60% by mass or more of a polycarbonate resin (thispolycarbonate resin is sometimes referred to as a “predetermined Npolycarbonate resin”), preferably an aromatic polycarbonate resin(sometimes referred to as a “predetermined N aromatic polycarbonateresin”), having a structural viscosity index N within a predeterminedrange. This is because the combination with the predetermined Npolycarbonate resin allows the synergistic effects that are typical of ametal salt compound and a polycarbosilane compound according to thesecond aspect of the present invention to be significantly produced. Thelargest amount of predetermined N polycarbonate resin, preferablypredetermined N aromatic polycarbonate resin, in the polycarbonate resinis generally, but not limited to, 100% by mass or less, preferably 90%by mass or less, and more preferably 85% by mass or less.

The predetermined N polycarbonate resins may be used alone, or two ormore of the predetermined N polycarbonate resins may be combined witheach other at any ratio.

In addition to the predetermined N polycarbonate resin, thepolycarbonate resin may contain a polycarbonate resin having astructural viscosity index N outside the predetermined range. Althoughthe type is not particularly limited, linear polycarbonate resins areparticularly preferred. A combination of a predetermined N polycarbonateresin with a linear polycarbonate resin has the advantage that the flameresistance (anti-dripping properties) and the formability (flowability)of the resulting polycarbonate resin composition can be easily balanced.In this regard, a polycarbonate resin containing a predetermined Npolycarbonate resin and a linear polycarbonate resin is particularlypreferably used.

The structural viscosity index N of the linear polycarbonate resingenerally ranges from approximately 1 to 1.15.

In the case where the polycarbonate resin contains a linearpolycarbonate resin, the percentage of the linear polycarbonate resin inthe polycarbonate resin is generally 80% by mass or less, preferably 50%by mass or less, and more preferably 40% by mass or less and generallymore than 0% by mass, preferably 10% by mass or more, and morepreferably 15% by mass or more. When the content of the linearpolycarbonate resin in the polycarbonate resin is set within the range,there can be provided the advantages that a metal salt compound servingas a flame retardant, a polycarbosilane compound, and other additiveagents can be easily dispersed and that a polycarbonate resin havinghigh flame resistance and formability can be easily produced.

The polycarbonate resin may contain only a polycarbonate resin having astructural viscosity index N outside the predetermined range alone ortwo or more of such polycarbonate resins at any ratio. That is, thepolycarbonate resin according to the second aspect of the presentinvention may contain only a linear polycarbonate resin or two or morelinear polycarbonate resins at any ratio.

[2-5. Method for Producing Predetermined N Polycarbonate Resin]

The predetermined N polycarbonate resin may be produced by the methodfor producing the polycarbonate resin. In this case, a polycarbonateresin having a branched structure (hereinafter sometimes referred to asa “branched polycarbonate resin”) is preferably produced because theproduction of the predetermined N polycarbonate resin is favorablyfacilitated. This is because the branched polycarbonate resin tends toincrease the structural viscosity index N.

Examples of a method for producing a branched polycarbonate resininclude methods described in Japanese Unexamined Patent ApplicationPublication No. 8-259687, Japanese Unexamined Patent ApplicationPublication No. 8-245782, and the like. In accordance with the methodsdescribed in these publications, the catalytic conditions ormanufacturing conditions in a reaction between an aromatic dihydroxycompound and a carbonic acid diester by a melt transesterificationmethod can be appropriately selected to produce a polycarbonate resinhaving a high structural viscosity index N and excellent hydrolyticstability without using a branching agent.

Another method for producing a branched polycarbonate resin is a methodin which a trifunctional or higher polyfunctional compound (branchingagent) and the raw materials of the polycarbonate resin, a dihydroxycompound and a carbonate precursor, are copolymerized by an interfacialpolymerization method or a melt transesterification method.

Examples of the trifunctional or higher polyfunctional compound usedherein include:

-   1,3,5-trihydroxybenzene(phloroglucin),-   4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-2,-   4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptane,-   2,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-3,-   1,3,5-tri(4-hydroxyphenyl)benzene,-   3,3-bis(4-hydroxyaryl)oxindole (or isatinbisphenol),-   5-chloroisatin,-   5,7-dichloroisatin,-   5-bromisatin, and the like;-   silicon-containing trisphenol compounds, such as-   C₆H₅—Si—(O—SiMe₂-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—(O—SiPh₂-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—(O—SiMe₂-C₂H₄—C₆H₄—OH)₃,-   C₆H₅—Si—(O—SiPh₂-C₂H₄—C₆H₄—OH)₃,-   C₆H₅—Si—([O—SiMe₂]₅-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—([O—SiMe₂]₁₀-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—([O—SiMe₂]₅₀-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—([O—SiPh₂]₅₀-C₃H₆—C₆H₄—OH)₃,-   C₆H₅—Si—([O—SiMe₂]₈-[O—SiPh₂]₂-C₃H₆—C₆H₄—OH)₃, and-   C₆H₅—Si—([O—SiMe₂]₁₆-[O—SiPh₂]₄-C₃H₆—C₆H₄—OH)₃,

(wherein Me represents a methyl group, and Ph represents a phenylgroup); and

polyhydroxy compounds, such as trisphenol compounds, represented by thefollowing formulae (8) and (9).

In the formula (8), R⁴ represents an alkyl group having 1 to 5 carbonatoms, and R⁵, R⁶, R⁷, R⁸, R⁹, and R¹⁰ each independently represent ahydrogen atom or an alkyl group having 1 to 10 carbon atoms.

In the formula (9), R¹¹, R¹², R¹³, and R¹⁴ each independently representan alkyl group having 1 to 10 carbon atoms, a cycloalkyl group having 5to 10 carbon atoms, or a cycloaryl group having 5 to 10 carbon atoms,and R¹⁵, R¹⁶, and R¹⁷ each independently represent a hydrogen atom or analkyl group having 1 to 10 carbon atoms.

Specific examples of the compound represented by the formula (8)include:

-   1,1,1-tris(4-hydroxyphenyl)-methane,-   1,1,1-tris(4-hydroxyphenyl)-ethane,-   1,1,1-tris(4-hydroxyphenyl)-propane,-   1,1,1-tris(2-methyl-4-hydroxyphenyl)-methane,-   1,1,1-tris(2-methyl-4-hydroxyphenyl)-ethane,-   1,1,1-tris(3-methyl-4-hydroxyphenyl)-methane,-   1,1,1-tris(3-methyl-4-hydroxyphenyl)-ethane,-   1,1,1-tris(3,5-dimethyl-4-hydroxyphenyl)-methane, and-   1,1,1-tris(3,5-dimethyl-4-hydroxyphenyl)-ethane.

In the formula (9), R¹¹, R¹², R¹³, and R¹⁴ are particularly preferably amethyl group. The cycloalkyl ring of the cycloalkyl group of R¹¹, R¹²,R¹³, and R¹⁴ may be substituted with an alkyl group having 1 to 4 carbonatoms, preferably a methyl group. R¹⁵, R¹⁶, and R¹⁷ are particularlypreferably a hydrogen atom.

The compound represented by the formula (9) is particularly preferably acompound represented by the following formula (10).

The polyfunctional compound may be used by substituting part of the rawmaterial dihydroxy compound. The amount of polyfunctional compound to beused is generally 0.01% by mole or more and preferably 0.1% by mole ormore and generally 10% by mole or less and preferably 3% by mole or lessof the dihydroxy compound.

The polyfunctional compounds may be used alone, or two or more of thepolyfunctional compounds may be combined with each other at any ratio.

Examples of the branched structure of the branched polycarbonate resinproduced by the melt transesterification method include the structuresrepresented by the following formulae (11) to (14). In the followingformulae (11) to (14), X², X³, X⁴, and X⁵ are selected from the groupconsisting of a single bond, an alkylene group having 1 to 8 carbonatoms, an alkylidene group having 2 to 8 carbon atoms, a cycloalkylenegroup having 5 to 15 carbon atoms, a cycloalkylidene group having 5 to15 carbon atoms, and divalent groups represented by —O—, —S—, —CO—,—SO—, and —SO₂—.

Among the above-described methods for producing the branchedpolycarbonate resin, a method involving the melt transesterificationmethod is particularly preferred. This is because the branchedpolycarbonate resin can be produced with relatively inexpensive andindustrially available raw materials, as described in the method forproducing a polycarbonate resin.

The description of [2-4. Other Matters regarding Polycarbonate Resin] inI. First Aspect of the Present Invention can be applied to [2-6. OtherMatters regarding Polycarbonate Resin] of the polycarbonate resin usedin the second aspect of the present invention.

3. Metal Salt Compound

The polycarbonate resin composition according to the second aspect ofthe present invention contains a metal salt compound. The metal saltcompound can improve the flame resistance of the polycarbonate resincomposition according to the second aspect of the present invention.

Examples of the metal of the metal salt compound include alkali metals,such as lithium (Li), sodium (Na), potassium (K), rubidium (Rb), andcesium (Cs); alkaline-earth metals, such as magnesium (Mg), calcium(Ca), strontium (Sr), and barium (Ba); and aluminum (Al), titanium (Ti),iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), zirconium(Zr), and molybdenum (Mo). Among these, alkali metals and alkaline-earthmetals are preferred.

This is because they can promote the formation of a carbonized layerduring the combustion of the polycarbonate resin composition accordingto the second aspect of the present invention, thereby improving flameresistance, and can maintain excellent mechanical properties, such asimpact resistance, heat resistance, and electrical characteristics ofthe polycarbonate resin. Thus, the metal salt compound is morepreferably at least one metal salt compound selected from the groupconsisting of alkali metal salts and alkaline-earth metal salts, stillmore preferably an alkali metal salt compound, and particularlypreferably a sodium salt compound, a potassium salt compound, and acesium salt compound.

Examples of the metal salt compounds include organic metal saltcompounds and inorganic metal salt compounds. In terms of dispersibilityin polycarbonate resins, organic metal salt compounds are preferred.

Examples of the organic metal salt compounds include organic sulfonicacid metal salts, organic sulfonamide metal salts, organic carboxylicacid metal salts, organic boric acid metal salts, and organic phosphoricacid metal salts. Among these, in terms of thermal stability when mixedwith a polycarbonate resin, organic sulfonic acid metal salts, organicsulfonamide metal salts, and organic phosphoric acid metal salts arepreferred, and organic sulfonic acid metal salts are particularlypreferred.

Examples of the organic sulfonic acid metal salts include organicsulfonic acid lithium (Li) salts, organic sulfonic acid sodium (Na)salts, organic sulfonic acid potassium (K) salts, organic sulfonic acidrubidium (Rb) salts, organic sulfonic acid cesium (Cs) salts, organicsulfonic acid magnesium (Mg) salts, organic sulfonic acid calcium (Ca)salts, organic sulfonic acid strontium (Sr) salts, and organic sulfonicacid barium (Ba) salts. Among these, organic sulfonic acid alkali metalsalts, such as organic sulfonic acid sodium (Na) salts, organic sulfonicacid potassium (K) salt compounds, and organic sulfonic acid cesium (Cs)salt compounds, are particularly preferred.

Preferred examples of the metal salt compound includefluorine-containing aliphatic sulfonic acid metal salts,fluorine-containing aliphatic sulfonimide metal salts, aromatic sulfonicacid metal salts, and aromatic sulfonamide metal salts. Among these,preferred specific examples include:

<Fluorine-Containing Aliphatic Sulfonic Acid Metal Salts>

fluorine-containing aliphatic sulfonic acid alkali metal salts having atleast one C—F bond in its molecule, such as potassiumperfluorobutanesulfonate, lithium perfluorobutanesulfonate, sodiumperfluorobutanesulfonate, cesium perfluorobutanesulfonate, lithiumtrifluoromethanesulfonate, sodium trifluoromethanesulfonate, potassiumtrifluoromethanesulfonate, potassium perfluoroethanesulfonate, andpotassium perfluoropropanesulfonate;

fluorine-containing aliphatic sulfonic acid alkaline-earth metal saltshaving at least one C—F bond in its molecule, such as magnesiumperfluorobutanesulfonate, calcium perfluorobutanesulfonate, bariumperfluorobutanesulfonate, magnesium trifluoromethanesulfonate, calciumtrifluoromethanesulfonate, and barium trifluoromethanesulfonate; and

fluorine-containing aliphatic disulfonic acid alkali metal salts havingat least one C—F bond in its molecule, such as disodiumperfluoromethanedisulfonate, dipotassium perfluoromethanedisulfonate,sodium perfluoroethanedisulfonate, dipotassiumperfluoroethanedisulfonate, dipotassium perfluoropropanedisulfonate,dipotassium perfluoroisopropanedisulfonate, disodiumperfluorobutanedisulfonate, dipotassium perfluorobutanedisulfonate, anddipotassium perfluorooctanedisulfonate;

<Fluorine-Containing Aliphatic Sulfonimide Metal Salts>

fluorine-containing aliphatic sulfonimide alkali metal salts having atleast one C—F bond in its molecule, such as lithiumbis(perfluoropropanesulfonyl)imide, sodiumbis(perfluoropropanesulfonyl)imide, potassiumbis(perfluoropropanesulfonyl)imide, lithiumbis(perfluorobutanesulfonyl)imide, sodiumbis(perfluorobutanesulfonyl)imide, potassiumbis(perfluorobutanesulfonyl)imide, potassiumtrifluoromethane(pentafluoroethane)sulfonylimide, sodiumtrifluoromethane(nonafluorobutane)sulfonylimide, and potassiumtrifluoromethane(nonafluorobutane)sulfonylimide; and

cyclic fluorine-containing aliphatic sulfonimide alkali metal saltshaving at least one C—F bond in its molecule, such as lithiumcyclo-hexafluoropropane-1,3-bis(sulfonyl)imide, sodiumcyclo-hexafluoropropane-1,3-bis(sulfonyl)imide, and potassiumcyclo-hexafluoropropane-1,3-bis(sulfonyl)imide;

<Aromatic Sulfonic Acid Metal Salts>

aromatic sulfonic acid alkali metal salts having at least one aromaticgroup in its molecule, such as dipotassiumdiphenylsulfone-3,3′-disulfonate, potassium diphenylsulfone-3-sulfonate,sodium benzenesulfonate, poly(sodium styrenesulfonate), sodiumparatoluenesulfonate, (branched) sodium dodecylbenzenesulfonate, sodiumtrichlorobenzenesulfonate, potassium benzenesulfonate, potassiumstyrenesulfonate, poly(potassium styrenesulfonate), potassiumparatoluenesulfonate, (branched) potassium dodecylbenzenesulfonate,potassium trichlorobenzenesulfonate, cesium benzenesulfonate,poly(cesium styrenesulfonate), cesium paratoluenesulfonate, (branched)cesium dodecylbenzenesulfonate, and cesium trichlorobenzenesulfonate;and

aromatic sulfonic acid alkaline-earth metal salts having at least onearomatic group in its molecule, such as magnesium paratoluenesulfonate,calcium paratoluenesulfonate, strontium paratoluenesulfonate, bariumparatoluenesulfonate, (branched) magnesium dodecylbenzenesulfonate, and(branched) calcium dodecylbenzenesulfonate; and

<Aromatic Sulfonamide Metal Salts>

aromatic sulfonamide alkali metal salts having at least one aromaticgroup in its molecule, such as saccharin sodium salt,N-(p-tolylsulfonyl)-p-toluene sulfonimide potassium salt,N—(N′-benzylaminocarbonyl)sulfanilimide potassium salt, andN-(phenylcarboxyl)-sulfanilimide potassium salt.

Among these examples, fluorine-containing aliphatic sulfonic acid metalsalts and aromatic sulfonic acid metal salts are more preferred, andfluorine-containing aliphatic sulfonic acid metal salts are particularlypreferred.

The fluorine-containing aliphatic sulfonic acid metal salts are morepreferably fluorine-containing aliphatic sulfonic acid alkali metalsalts having at least one C—F bond in its molecule and particularlypreferably perfluoroalkane sulfonic acid alkali metal salts. Morespecifically, potassium perfluorobutanesulfonate is preferred.

The aromatic sulfonic acid metal salts are more preferably aromaticsulfonic acid alkali metal salts; particularly preferablydiphenylsulfone-sulfonic acid alkali metal salts, such as dipotassiumdiphenylsulfone-3,3′-disulfonate and potassiumdiphenylsulfone-3-sulfonate, and paratoluenesulfonic acid alkali metalsalts, such as sodium paratoluenesulfonate, potassiumparatoluenesulfonate, and cesium paratoluenesulfonate; and still morepreferably paratoluenesulfonic acid alkali metal salts.

These metal salt compounds may be used alone, or two or more of themetal salt compounds may be combined with each other at any ratio.

The content of metal salt compound in the polycarbonate resincomposition according to the second aspect of the present invention is0.01 parts by mass or more, preferably 0.02 parts by mass or more, morepreferably 0.03 parts by mass or more, and particularly preferably 0.05parts by mass or more and 1 part by mass or less, preferably 0.75 partsby mass or less, more preferably 0.5 parts by mass or less, andparticularly preferably 0.3 parts by mass or less relative to 100 partsby mass of the polycarbonate resin. An excessively low content of metalsalt compound may result in insufficient flame resistance of theresulting polycarbonate resin composition. On the other hand, anexcessively high content of metal salt compound may result in reducedthermal stability of the polycarbonate resin composition and poorappearance and low mechanical strength of a formed product.

4. Polycarbosilane Compound

The polycarbonate resin composition according to the second aspect ofthe present invention contains a polycarbosilane compound, that is, asilicon compound having a silicon-carbon bond in the main chain. Inaccordance with the second aspect of the present invention, acombination of the polycarbosilane compound and a metal salt compoundcan markedly improve the flame resistance of the polycarbonate resincomposition according to the second aspect of the present invention. Apolycarbonate resin composition having higher transparency, impactresistance, and heat resistance and causing less outgassing and moldfouling can be produced using a polycarbosilane compound according tothe second aspect of the present invention compared with the case wherea conventional organosiloxane (silicone) compound or polysilane compoundis used. The reason for this is described below.

Conventional organosiloxanes (silicones) are silicon compounds having asilicon-oxygen bond as the main chain. Polysilane compounds are siliconcompounds having a silicon-silicon bond as the main chain. These siliconcompounds therefore have strong inorganic characteristics andconsequently poor compatibility with and dispersibility in polycarbonateresins, which are organic resins. Thus, these silicon compounds tend tocause poor mechanical properties, such as impact resistance, and poortransparency.

In particular, since organosiloxanes generally have low melting points,the blend of the organosiloxanes with polycarbonate resins tends tocause low heat resistance of their resin compositions and increasedoutgassing, which tends to cause mold fouling. Use of organosiloxaneshaving lower molecular weights so as to achieve higher transparencyincreases outgassing and mold fouling. Although polysilane compoundstend to be better in terms of heat resistance than organosiloxanecompounds, because of the same reasons as described above, use of thepolysilane compounds results in markedly poor mechanical properties,possibly low transparency, and increased outgassing and mold fouling.

In contrast, polycarbosilane compounds having a silicon-carbon bond inthe main chain contain an organic moiety (organic residue) in the mainchain and have more organic characteristics. Polycarbosilane compoundstherefore have much higher dispersibility in polycarbonate resins thanorganosiloxanes or polysilane compounds and can improve the flameresistance of the polycarbonate resin composition without causingdeterioration in mechanical properties, such as impact resistance, andtransparency. Furthermore, a polycarbosilane compound according to thesecond aspect of the present invention has high heat resistance,resulting in reduced deterioration in the heat resistance of apolycarbonate resin composition and markedly reduced outgassing and moldfouling.

In a method for improving flame resistance with an organosiloxane(silicone) compound, a silicon-oxygen bond of organosiloxane is believedto be important because the silicon-oxygen bond is converted into a SiO₂component during combustion to improve flame resistance. However, as aresult of studies performed by the inventors, it was found that a bondbetween a silicon atom and a side chain (for example, a methyl group ora phenyl group), that is, a silicon-carbon bond of organosiloxanecontributed to flame resistance more than the silicon-oxygen bond. Thisis probably because organic components are vaporized by the cleavage ofthe silicon-carbon bond during combustion to form a foam layer.

Since the polycarbosilane compound according to the second aspect of thepresent invention has a silicon-carbon bond in the main chain as well asthe side chains, the polycarbosilane compound has the advantage that itcan improve flame resistance more efficiently than organosiloxane andpolysilane compounds.

The polycarbosilane compound according to the second aspect of thepresent invention may contain a bond between a silicon atom and an atomother than carbon in the main chain without departing from the object ofthe second aspect of the present invention. Examples of such a bondinclude a silicon-silicon (Si—Si) bond, a silicon-oxygen (Si—O) bond, asilicon-nitrogen (Si—N) bond, a silicon-boron (Si—B) bond, asilicon-phosphorus (Si—P) bond, and a silicon-titanium (Si—Ti) bond.Such a bond may be introduced from components, such as raw materials andcatalysts, or may be unintentionally introduced by oxidation or otheractions during the production of silicon compounds substantially havinga silicon-carbon bond alone.

A polycarbosilane compound used in the second aspect of the presentinvention is the same as the polycarbosilane compound used in the firstaspect of the present invention. Thus, the description of [3.Polycarbosilane Compound] in I. First Aspect of the Present Inventioncan be applied.

The content of the polycarbosilane compound in the polycarbonate resincomposition according to the second aspect of the present invention is0.005 parts by mass or more, preferably 0.01 parts by mass or more, morepreferably 0.02 parts by mass or more, particularly preferably 0.05parts by mass or more, and most preferably 0.1 parts by mass or more and5 parts by mass or less, preferably 3 parts by mass or less, morepreferably 2 parts by mass or less, and particularly preferably 1 partby mass or less relative to 100 parts by mass of the polycarbonateresin. An excessively low content of polycarbosilane compound may resultin insufficient flame resistance of the resulting polycarbonate resincomposition. On the other hand, at an excessively high content ofpolycarbosilane compound, its effect may be leveled off and thus its usemay be uneconomical, and the polycarbonate resin composition may havelow mechanical strength.

The polycarbosilane compound according to the second aspect of thepresent invention may be used alone or in combination.

5. Other Components

The polycarbonate resin composition according to the second aspect ofthe present invention may optionally contain components other than thosedescribed above provided that desired physical properties are notsignificantly deteriorated. Examples of the other components includeresins other than polycarbonate resins and various resin additiveagents. The other components may be contained alone, or two or more ofthe other components may be contained at any ratio.

The description of <Other Resins> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to <Other Resins> that may be containedin the polycarbonate resin composition according to the second aspect ofthe present invention.

<Resin Additive Agents>

Examples of the resin additive agents include a heat stabilizer, anantioxidant, a mold-release agent, an ultraviolet absorber, a dye orpigment, a flame retardant, an anti-dripping agent, a light-diffusingagent, an antistatic agent, an anti-fogging agent, a lubricant, ananti-blocking agent, a flow modifier, a sliding modifier, a plasticizer,a dispersant, and an antimicrobial agent. The resin additive agents maybe contained alone, or two or more of the resin additive agents may becontained at any ratio.

The descriptions of Heat Stabilizer, Antioxidant, Mold-Release Agent,Ultraviolet Absorber, Dye or Pigment, and Anti-Dripping Agent of <ResinAdditive Agents> that may be contained in the polycarbonate resincomposition according to I. First Aspect of the Present Invention can beapplied to exemplary resin additive agents Heat Stabilizer, Antioxidant,Mold-Release Agent, Ultraviolet Absorber, Dye or Pigment, andAnti-Dripping Agent suitable for the polycarbonate resin compositionaccording to the second aspect of the present invention, respectively.

[Light-Diffusing Agent]

A light-diffusing agent contains inorganic or organic fine particles.Examples of the light-diffusing agent include glass fine particles andorganic fine particles of, for example, polystyrene resins,(meth)acrylic resins, and silicone resins. Organic fine particles arepreferred in terms of light diffusion and particle dispersion.

The organic fine particles of the light-diffusing agent are preferablycross-linked organic fine particles that do not melt in thepolycarbonate resin even when heated to the shaping temperature of thepolycarbonate resin. Thus, cross-linked (meth)acrylic resins andcross-linked silicone resins are preferred. Specific examples thereofinclude partially cross-linked polymethyl methacrylate polymer fineparticles, cross-linked silicone resin particles, and silicone rubberpowders containing silicone rubber coated with a silicone resin.

The shape of the light-diffusing agent is preferably spherical in termsof light-diffusing effects.

The average particle size of the particulate light-diffusing agentpreferably ranges from 0.1 to 50 μm, more preferably 0.5 to 10 μm, andparticularly 1 to 5 μm. An excessively small average particle size ofthe light-diffusing agent results in insufficient light dispersioneffects. An excessively large average particle size may result in arough surface or low mechanical strength of formed products. The averageparticle size of the light-diffusing agent refers to a volume-averageparticle size measured by a Coulter counter method. The Coulter countermethod can determine the particle size by passing sample particlessuspended in an electrolyte through a pore (aperture) and reading achange in voltage pulse generated in proportion to the particle volume.Furthermore, the voltage pulse height can be measured one by one toprepare the volume distribution histogram of the sample particles. Themeasurements of the particle size or the particle size distribution bythe Coul counter method are most frequently used as a particle sizedistribution analysis.

In the second aspect of the present invention, two or morelight-diffusing agents made of different materials or having differentaverage particle sizes may be used in combination.

In the case where the polycarbonate resin composition according to thesecond aspect of the present invention contains a light-diffusing agent,the preferred content of the light-diffusing agent generally ranges from0.1 to 20 parts by mass and more preferably 0.3 to 10 parts by massrelative to 100 parts by mass of the polycarbonate resin. An excessivelylow content of light-diffusing agent results in insufficient lightdiffusion. Thus, a light source tends to be seen through a formedproduct, resulting in an insufficient effect of reducing glare. Anexcessively high content of light-diffusing agent results ininsufficient luminance.

6. Method for Producing Polycarbonate Resin Composition

A method for producing the polycarbonate resin composition according tothe second aspect of the present invention is not particularly limited.Various known methods for producing polycarbonate resin compositions canbe employed.

A specific example is a method in which a polycarbonate resin, a metalsalt compound, a polycarbosilane compound, and other components to beoptionally blended are mixed in advance, for example, in a mixer, suchas a tumbler or a Henschel mixer, and are melt-kneaded in a mixer, suchas a Banbury mixer, a roll, a Brabender, a single-screw extruder, atwin-screw extruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and then melt-kneaded to producethe polycarbonate resin composition according to the second aspect ofthe present invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and melt-kneaded to produce the polycarbonate resincomposition according to the second aspect of the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

7. Polycarbonate Resin Formed Product

The polycarbonate resin composition according to the second aspect ofthe present invention can generally be formed into polycarbonate resinformed products having any shape. The shape, design, color, and size ofthe formed products are not particularly limited and may beappropriately determined in accordance with each application of theformed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators. Among these, the formed products aresuitably used for components of electrical and electronic devices, OAequipment, information terminals, household electrical appliances, andilluminators and are particularly suitably used for components ofelectrical and electronic devices.

Examples of the electrical and electronic devices include personalcomputers, game machines, display units, such as television sets,printers, copying machines, scanners, facsimiles, electronic notebooksand PDAs, electronic calculators, electronic dictionaries, cameras,video cameras, cellular phones, battery packs, recording medium drivesand readers, mouses, numeric keypads, CD players, MD players, andportable radios and audio-players.

A method for manufacturing formed products is not particularly limited.Any common molding method for polycarbonate resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies, afoam molding (including supercritical fluid) method, an insert moldingmethod, an IMC (in-mold coating molding) molding method, an extrusionmolding method, a sheet forming method, a thermoforming method, arotational molding method, a laminate molding method, and a pressforming method. A hot-runner molding method may also be used.

The polycarbonate resin formed product according to the second aspect ofthe present invention obtained by shaping the polycarbonate resincomposition according to the second aspect of the present invention hasexcellent transparency, flame resistance, mechanical properties, andother characteristics, without adversely affecting the excellentintrinsic characteristics of polycarbonate resins. Thus, thepolycarbonate resin formed product can be used as a practical formedproduct in a wide variety of applications.

III. Third Aspect of the Present Invention 1. Overview

A thermoplastic resin composition according to a third aspect of thepresent invention contains at least a thermoplastic resin, afluoropolymer, and a polycarbosilane compound serving as a fluoropolymerdispersant. The thermoplastic resin composition according to the thirdaspect of the present invention may optionally contain a flame retardantand other components.

Polycarbosilane compounds are compounds having two or more repeatingunits each having a silicon-carbon bond (Si—C bond) in their mainchains. The polycarbosilane compound used in the third aspect of thepresent invention has the Si—C bond in its main chain and thus hassignificant effects of improving the compatibility and dispersibility ofthe fluoropolymer in thermoplastic resins. Consequently, there can besolved the problems of existing thermoplastic resin compositionscontaining a fluoropolymer, such as low light transmittance,particularly low transmittance of near-infrared light, poor appearance,and strength reduction.

2. Thermoplastic Resin

Examples of thermoplastic resins for use in the thermoplastic resincomposition according to the third aspect of the present inventioninclude, but are not limited to:

polycarbonate resins (PC resins), such as aromatic polycarbonate resinsand aliphatic polycarbonate resins;

thermoplastic polyester resins, such as a polyethylene terephthalateresin (PET resin), polytrimethylene terephthalate (PTT resin), apolybutylene terephthalate resin (PBT resin), polylactic acid (PLA), apolybutylene succinate resin (PBS), and polycaprolactone (PCL);

styrene resins, such as a polystyrene resin (PS resin), a high-impactpolystyrene resin (HIPS), an acrylonitrile-styrene copolymer (AS resin),an acrylonitrile-butadiene-styrene copolymer (ABS resin), anacrylonitrile-styrene-acrylic rubber copolymer (ASA resin), and anacrylonitrile-ethylene propylene rubber-styrene copolymer (AES resin);

polyolefin resins, such as a polyethylene resin (PE resin), apolypropylene resin (PP resin), a cyclic cycloolefin resin (COP resin),and a cyclic cycloolefin copolymer (COC resin); and

polyamide resins (PA resins); polyimide resins (PI resins);polyetherimide resins (PEI resins); polyurethane resins (PU resins);polyphenylene ether resins (PPE resins); polyphenylene sulfide resins(PPS resins); polysulfone resins (PSU resins); and polymethylmethacrylate resins (PMMA resins).

The thermoplastic resin composition according to the third aspect of thepresent invention may contain one of these thermoplastic resins or anycombination of two or more of these thermoplastic resins at any ratio.

In particular, in the third aspect of the present invention, among thesethermoplastic resins, because of excellent optical properties, such astransparency, heat resistance, mechanical properties, and electricalcharacteristics, polycarbonate resins are preferably used, and aromaticpolycarbonate resins are particularly preferably used. Preferably, 50%or more, particularly 70% by mass or more, of the thermoplastic resincontained in the thermoplastic resin composition according to the thirdaspect of the present invention is a polycarbonate resin, particularlyan aromatic polycarbonate resin. Polycarbonate resins may be used alone,or two or more polycarbonate resins may be combined with each other atany ratio.

The polycarbonate resin is a polymer having a basic structure having acarbonate bond represented by the following formula (7):

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins may be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

In the third aspect of the present invention, the descriptions of [2-1.Dihydroxy Compound], [2-2. Carbonate Precursor], [2-3. Method forProducing Polycarbonate Resin], and [2-4. Other Matters regardingPolycarbonate Resin] in the first aspect of the present invention can beapplied to [2-1. Dihydroxy Compound], [2-2. Carbonate Precursor], [2-3.Method for Producing Polycarbonate Resin], and [2-4. Other Mattersregarding Polycarbonate Resin] of the polycarbonate resin, respectively.

3. Fluoropolymer

The thermoplastic resin composition according to the third aspect of thepresent invention contains a fluoropolymer, for the purpose of modifyingthe melt properties (for example, anti-dripping properties duringcombustion) and surface properties, such as sliding characteristics,abrasion resistance, water repellency, oil repellency, stain resistance,and fingerprint resistance, of the thermoplastic resin.

The fluoropolymer used in the third aspect of the present invention isparticularly preferably a fluoroolefin resin.

The fluoroolefin resin is generally a polymer or copolymer having afluoroethylene structure. Specific examples thereof includedifluoroethylene resins, tetrafluoroethylene resins, andtetrafluoroethylene/hexafluoropropylene copolymer resins. Among these,tetrafluoroethylene resins are preferred.

In particular, the fluoropolymer is preferably a fluoropolymer capableof forming fibrils, more specifically a fluoroolefin resin capable offorming fibrils. The fluoropolymer capable of forming fibrils tends tomarkedly improve the anti-dripping properties during combustion.

Examples of commercially available fluoroolefin resins capable offorming fibrils include “Teflon (registered trademark) 6J” manufacturedby DuPont-Mitsui Fluorochemicals Co., Ltd. and “Polyflon (registeredtrademark) F201L” and “Polyflon (registered trademark) F103”manufactured by Daikin Industries, Ltd. Examples of commerciallyavailable aqueous fluoroolefin resin dispersions include “Teflon(registered trademark) 30J” and “Teflon (registered trademark) 31-JR”manufactured by DuPont-Mitsui Fluorochemicals Co., Ltd. and “Fluon(registered trademark) D-1” manufactured by Daikin Industries, Ltd.

Organic-polymer-coated fluoroolefin resins may also be suitably used asthe fluoropolymer. The organic-polymer-coated fluoroolefin resins canimprove dispersibility and the surface appearance of formed products andreduce surface foreign substances. The organic-polymer-coatedfluoroolefin resins can be produced by known various methods, forexample, (1) a method in which an aqueous polyfluoroethylene particledispersion and an aqueous organic polymer particle dispersion are mixedand powdered by coagulation or spray-drying, (2) a method in whichmonomers of the organic polymer are polymerized in the presence of anaqueous polyfluoroethylene particle dispersion and the resultant polymeris powdered by coagulation or spray-drying, and (3) a method in whichmonomers having an ethylenically unsaturated bond are subjected toemulsion polymerization in a mixed dispersion liquid of an aqueouspolyfluoroethylene particle dispersion and an aqueous organic polymerparticle dispersion and the resultant polymer is powdered by coagulationor spray-drying.

The organic polymer coating the fluoroolefin resin is not particularlylimited. Specific examples of monomers for use in the production of theorganic polymer include:

aromatic vinyl monomers, such as styrene, α-methylstyrene,p-methylstyrene, o-methylstyrene, tert-butylstyrene, o-ethylstyrene,p-chlorostyrene, o-chlorostyrene, 2,4-dichlorostyrene, p-methoxystyrene,o-methoxystyrene, and 2,4-dimethylstyrene;

(meth)acrylate monomers, such as methyl acrylate, methyl methacrylate,ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate,2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, dodecyl acrylate,dodecyl methacrylate, tridecyl acrylate, tridecyl methacrylate,octadecyl acrylate, octadecyl methacrylate, cyclohexyl acrylate, andcyclohexyl methacrylate;

vinyl cyanide monomers, such as acrylonitrile and methacrylonitrile;

α,β-unsaturated carboxylic acids, such as maleic anhydride;

maleimide monomers, such as N-phenylmaleimide, N-methylmaleimide, andN-cyclohexylmaleimide;

monomers containing a glycidyl group, such as glycidyl methacrylate;

vinyl ether monomers, such as vinyl methyl ether and vinyl ethyl ether;

vinyl carboxylate monomers, such as vinyl acetate and vinyl butyrate;

olefin monomers, such as ethylene, propylene, and isobutylene; and

diene monomers, such as butadiene, isoprene, and dimethylbutadiene.

These monomers may be used alone or in combination.

Among these, in the case where the thermoplastic resin is apolycarbonate resin, the monomers for producing the organic polymercoating the fluoroolefin resin are preferably monomers having a highaffinity for polycarbonate resins in terms of dispersibility of themonomers in polycarbonate resins. Aromatic vinyl monomers,(meth)acrylate monomers, and vinyl cyanide monomers are more preferred.

The content ratio of the fluoroolefin resin in theorganic-polymer-coated fluoroolefin resin is generally 30% by mass ormore, preferably 35% by mass or more, more preferably 40% by mass ormore, and particularly preferably 45% by mass or more and generally 95%by mass or less, preferably 90% by mass or less, more preferably 80% bymass or less, and particularly preferably 75% by mass or less. When thecontent ratio of the fluoroolefin resin in the organic-polymer-coatedfluoroolefin resin is within the above-described range, a good balancebetween flame resistance and appearance of formed products tends to befavorably achieved.

Examples of commercially available organic-polymer-coated fluoroolefinresins include “Metablen (registered trademark) A-3800” manufactured byMITSUBISHI RAYON Co., Ltd., “Blendex (registered trademark) 449”manufactured by GE Speciality Chemicals Inc., and “Poly TS AD001”manufactured by PIC.

The fluoropolymers may be contained alone, or two or more of thefluoropolymers may be contained at any ratio.

The content of the fluoropolymer in the thermoplastic resin compositionaccording to the third aspect of the present invention is generally0.001 parts by mass or more, preferably 0.005 parts by mass or more,more preferably 0.01 parts by mass or more, and particularly preferably0.02 parts by mass or more and generally 3 parts by mass or less,preferably 2 parts by mass or less, more preferably 1 part by mass orless, and particularly preferably 0.5 parts by mass or less relative to100 parts by mass of the thermoplastic resin. A fluoropolymer contentless than or equal to the lower limit may result in an insufficienteffect supposed to be produced by the blend of the fluoropolymer. Afluoropolymer content more than the upper limit may result in poorappearance, low mechanical strength, or significantly low transmittancein a near-infrared region or transparency of formed products obtained byshaping the thermoplastic resin composition.

4. Polycarbosilane Compound

The thermoplastic resin composition according to the third aspect of thepresent invention contains a polycarbosilane compound serving as afluoropolymer dispersant, that is, a silicon compound having asilicon-carbon bond in the main chain. In accordance with the thirdaspect of the present invention, the polycarbosilane compound improvesthe compatibility and dispersibility of the fluoropolymer in thethermoplastic resin composition according to the third aspect of thepresent invention, light transmittance, particularly transmittance ofnear-infrared light, and flame resistance, thereby suppressing poorappearance and strength reduction.

This is because the polycarbosilane compound having a silicon-carbonbond in the main chain contains an organic moiety (organic residue) inthe main chain and have more organic characteristics and can thereforeeffectively improve the compatibility and dispersibility of thefluoropolymer in thermoplastic resins.

A polycarbosilane compound according to the third aspect of the presentinvention may contain a bond between a silicon atom and an atom otherthan carbon in the main chain without departing from the object of thethird aspect of the present invention. Examples of such a bond include asilicon-silicon (Si—Si) bond, a silicon-oxygen (Si—O) bond, asilicon-nitrogen (Si—N) bond, a silicon-boron (Si—B) bond, asilicon-phosphorus (Si—P) bond, and a silicon-titanium (Si—Ti) bond.Such a bond may be introduced from components, such as raw materials andcatalysts, or may be unintentionally introduced by oxidation or otheractions during the production of silicon compounds substantially havinga silicon-carbon bond alone.

A polycarbosilane compound used in the third aspect of the presentinvention is the same as the polycarbosilane compound used in the firstaspect of the present invention. Thus, the description of [3.Polycarbosilane Compound] in I. First Aspect of the Present Inventioncan be applied.

The content of the polycarbosilane compound in the thermoplastic resincomposition according to the third aspect of the present invention ispreferably 0.005 parts by mass or more, more preferably 0.01 parts bymass or more, still more preferably 0.02 parts by mass or more,particularly preferably 0.05 parts by mass or more, and most preferably0.75 parts by mass or more and preferably 10 parts by mass or less, morepreferably 7.5 parts by mass or less, still more preferably 3 parts bymass or less, and particularly preferably 1.75 parts by mass or lessrelative to 100 parts by mass of the thermoplastic resin. An excessivelylow content of polycarbosilane compound may result in insufficienteffects of improving the compatibility and dispersibility of thefluoropolymer in thermoplastic resins. On the other hand, at anexcessively high content of polycarbosilane compound, its effect may beleveled off and thus its use may be uneconomical, and the thermoplasticresin composition may have low mechanical strength.

The polycarbosilane compound according to the third aspect of thepresent invention may be used alone or in combination.

5. Flame Retardant

The thermoplastic resin composition according to the third aspect of thepresent invention may further contain a flame retardant, and thecombination of the flame retardant with the fluoropolymer can providesignificantly high flame resistance.

Any known flame retardant may be suitably selected. Examples of such aflame retardant include a halogen-based flame retardant, aphosphorus-based flame retardant, a nitrogen-based flame retardant, aboron-based flame retardant, a metal salt-based flame retardant, asilicone-based flame retardant, and an inorganic compound-based flameretardant. Among these, a metal salt-based flame retardant (hereinaftersometimes referred to as “metal salt compound”) can be preferably usedbecause it does not easily cause a reduction in the light transmittance,particularly transmittance of near-infrared light, and mechanicalproperties of the thermoplastic resin composition and produces lesseffects on environment and human bodies. The combination of the metalsalt compound with the thermoplastic resin that can be suitably used inthe third aspect of the present invention can effectively provide flameresistance.

Examples of the metal of the metal salt compound include alkali metals,such as lithium (Li), sodium (Na), potassium (K), rubidium (Rb), andcesium (Cs); alkaline-earth metals, such as magnesium (Mg), calcium(Ca), strontium (Sr), and barium (Ba); and aluminum (Al), titanium (Ti),iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), zirconium(Zr), and molybdenum (Mo). Among these, alkali metals and alkaline-earthmetals are preferred.

This is because they can promote the formation of a carbonized layerduring the combustion of the thermoplastic resin composition accordingto the third aspect of the present invention, thereby improving flameresistance, and can maintain excellent mechanical properties, such asimpact resistance, heat resistance, and electrical characteristics ofthe polycarbonate resin. Thus, the metal salt compound is morepreferably at least one metal salt compound selected from the groupconsisting of alkali metal salts and alkaline-earth metal salts, stillmore preferably an alkali metal salt compound, and particularlypreferably a sodium salt compound, a potassium salt compound, or acesium salt compound.

Examples of the metal salt compound include organic metal salt compoundsand inorganic metal salt compounds. In terms of dispersibility inthermoplastic resins, organic metal salt compounds are preferred.

The description of [3. Metal Salt Compound] in II. Second Aspect of thePresent Invention can be applied to the metal salt compound used in thethird aspect of the present invention.

The content of the flame retardant in the thermoplastic resincomposition according to the third aspect of the present invention ispreferably 0.001 parts by mass or more, more preferably 0.02 parts bymass or more, and still more preferably 0.05 parts by mass or more andpreferably 30 parts by mass or less, more preferably 20 parts by mass orless, and still more preferably 10 parts by mass or less relative to 100parts by mass of the thermoplastic resin.

In the case that the flame retardant in the thermoplastic resincomposition according to the third aspect of the present invention isthe metal salt compound described above, the content of the flameretardant is preferably 0.001 parts by mass or more, more preferably0.02 parts by mass or more, still more preferably 0.03 parts by mass ormore, and particularly preferably 0.05 parts by mass or more andpreferably 30 parts by mass or less, more preferably 20 parts by mass orless, still more preferably 10 parts by mass or less, and particularlypreferably 1 part by mass or less.

An excessively low content of metal salt compound has insufficienteffects, of improving the flame resistance of the thermoplastic resincomposition, supposed to be produced by the blend thereof. On the otherhand, an excessively high content of metal salt compound may result inreduced thermal stability of the thermoplastic resin composition andpoor appearance and low mechanical strength of a formed product.

6. Other Components

The thermoplastic resin composition according to the third aspect of thepresent invention may optionally contain various resin additive agentsas components other than those described above, provided that desiredphysical properties are not significantly deteriorated.

Examples of the resin additive agents include a heat stabilizer, anantioxidant, a mold-release agent, an ultraviolet absorber, a dye orpigment, a fibrous reinforcement, an optical function regulator, a flameretardant, an antistatic agent, an anti-fogging agent, a lubricant, ananti-blocking agent, a flow modifier, a sliding modifier, a plasticizer,a dispersant, and an antimicrobial agent. The resin additive agents maybe contained alone, or two or more of the resin additive agents may becontained at any ratio.

The descriptions of Heat Stabilizer, Antioxidant, Mold-Release Agent,Ultraviolet Absorber, and Dye or Pigment in <Resin Additive Agents> thatmay be contained in the polycarbonate resin composition according to I.First Aspect of the Present Invention can be applied to resin additiveagents Heat Stabilizer, Antioxidant, Mold-Release Agent, UltravioletAbsorber, and Dye or Pigment, respectively, suitable for thethermoplastic resin composition according to the third aspect of thepresent invention. Their amounts to be blended may be determined byreplacing the polycarbonate resin in the polycarbonate resin compositionwith the thermoplastic resin in the thermoplastic resin composition.

[Fibrous Reinforcement]

Examples of the fibrous reinforcement include glass fibers, carbonfibers, various metal fibers, and whiskers, which are used asreinforcements for thermoplastic resins, and glass fibers or carbonfibers are preferably used.

The blend of the fibrous reinforcement with the thermoplastic resincomposition according to the third aspect of the present inventionprovides a resin composition that achieves a formed product having highmechanical strength required for electrical and electronic devices, OAequipment, and the like.

A fibrous reinforcement having a large diameter has poor flexibility anda fibrous reinforcement having a small diameter of less than 1 μm is noteasily available. Therefore, the average diameter (average fiberdiameter) of the fibrous reinforcement is generally 1 to 100 μm and morepreferably 2 to 50 μm. In consideration of availability and effects as areinforcement, a fibrous reinforcement having an average diameter of 3to 30 μm, particularly 5 to 20 μm, is preferably used.

The length of the fibrous reinforcement is preferably 0.1 mm or more interms of reinforcement effects. The upper limit of the length of thefibrous reinforcement is generally 20 mm. A fibrous reinforcement havinga length larger than the upper limit is generally shortened due tobreaking when a resin composition is prepared by melt-kneading. Afibrous reinforcement having an average length of 0.3 to 5 mm ispreferably used.

The fibrous reinforcement is generally used in the form of a choppedstrand obtained by chopping a bunch of fibers so as to have a certainlength. The blend of carbon fibers imparts conductivity to resincompositions. If a resin composition having high resistance is desired,glass fibers are used.

In the case where the fibrous reinforcement is blended with thethermoplastic resin composition according to the third aspect of thepresent invention, the content of the fibrous reinforcement in thethermoplastic resin composition is generally 5 to 100 parts by massrelative to 100 parts by mass of the thermoplastic resin. A fibrousreinforcement content of less than 5 parts by mass results in a smallreinforcement effect, and a fibrous reinforcement content of more than100 parts by mass deteriorates the mechanical properties, such as impactresistance, of the resin composition. The preferred content of thefibrous reinforcement in the thermoplastic resin composition of thepresent invention is 10 to 70 parts by mass, particularly 15 to 50 partsby mass, relative to 100 parts by mass of the thermoplastic resin.

[Optical Function Regulator]

An optical function regulator improves the light-shielding effect,whiteness, and light reflection characteristics of a formed productobtained from the thermoplastic resin composition according to the thirdaspect of the present invention. Specifically, titanium oxide is used asthe optical function regulator.

The production method, crystal form, and average particle size oftitanium oxide used in the third aspect of the present invention are notparticularly limited, but are preferably as follows.

The production method of titanium oxide includes a sulfuric acid methodand a chlorine method. Since titanium oxide produced by the sulfuricacid method tends to be inferior in terms of the whiteness of acomposition containing the titanium oxide, titanium oxide is suitablyproduced by the chlorine method in order to effectively achieve theobject provided by blending an optical function regulator.

The crystal form of titanium oxide includes a rutile type and an anatasetype, and a rutile type crystal form is preferred in terms of lightresistance.

The average particle size of titanium oxide is generally 0.1 to 0.7 μmand preferably 0.1 to 0.4 μm. Titanium oxide having an average particlesize of less than 0.1 μm produces a poor light-shielding effect offormed products. Titanium oxide having an average particle size of morethan 0.7 μm results in a rough surface and reduced mechanical strengthof formed products. Herein, the average particle size of titanium oxideis an average value of primary particle sizes measured using atransmission electron microscope (TEM).

In the present invention, two or more titanium oxides having differentaverage particle sizes may be used in combination.

The titanium oxide used in the third aspect of the present invention maybe subjected to surface treatment.

An example of a surface-treating agent used herein is anorganosiloxane-based surface-treating agent. Before surface treatment isperformed with the organosiloxane-based surface-treating agent,pretreatment is preferably performed with an alumina-basedsurface-treating agent or a combination of an alumina-basedsurface-treating agent and a silica-based surface-treating agent.Titanium oxide pretreated with an alumina-based surface-treating agentand optionally a silica-based surface-treating agent is subjected tosurface treatment with an organosiloxane-based surface-treating agent toconsiderably improve the thermal stability and further favorably improvethe uniform dispersibility and the stability of dispersion state in thethermoplastic resin composition.

An alumina hydrate is suitably used as the alumina-basedsurface-treating agent. A silica hydrate is suitably used as thesilica-based surface-treating agent. Any pretreatment method can beemployed. The pretreatment is preferably performed so that 1 to 15% bymass of alumina-based surface-treating agent, such as alumina hydrate,and optionally silica-based surface-treating agent, such as silicahydrate, are used with respect to titanium oxide. That is, in the casewhere the pretreatment is performed with only an alumina-basedsurface-treating agent, 1 to 15% by mass of alumina-basedsurface-treating agent is preferably used with respect to the titaniumoxide additive agent. In the case where both an alumina-basedsurface-treating agent and a silica-based surface-treating agent areused, the total amount thereof is preferably 1 to 15% by mass withrespect to the titanium oxide additive agent. Herein, in the case whereboth an alumina-based surface-treating agent and a silica-basedsurface-treating agent are used, the amount of silica-basedsurface-treating agent is preferably about 35 to 90% by mass relative tothe total amount of alumina-based surface-treating agent andsilica-based surface-treating agent.

A polyorganohydrogensiloxane compound is preferably used as theorganosiloxane-based surface-treating agent.

The method for surface-treating titanium oxide with theorganosiloxane-based surface-treating agent includes a wet method and adry method.

The wet method is a method in which pretreated titanium oxide is addedto a mixture solution of an organosiloxane-based surface-treating agentand a solvent, stirring and desolvation are performed, and then heattreatment is performed at 100 to 300° C. Examples of the dry methodinclude a method in which pretreated titanium oxide and anorganosiloxane-based surface-treating agent are mixed using a Henschelmixer or the like and a method in which an organic solvent containing anorganosiloxane-based surface-treating agent is sprayed onto pretreatedtitanium oxide and heat treatment is performed at 100 to 300° C.

The degree of surface treatment of the pretreated titanium oxideadditive agent performed with the organosiloxane-based surface-treatingagent is not particularly limited. However, in consideration of thereflectivity of titanium oxide and the moldability of a resincomposition to be obtained, the amount of organosiloxane-basedsurface-treating agent is generally 1 to 5% by mass with respect totitanium oxide.

In the case where titanium oxide serving as an optical functionregulator is used in the thermoplastic resin composition according tothe third aspect of the present invention, the blending amount is 3 to30 parts by mass relative to 100 parts by mass of the thermoplasticresin. Titanium oxide having a blending amount of less than 3 parts bymass causes insufficient light-shielding effects and reflectioncharacteristics of the resultant formed product. Titanium oxide having ablending amount of more than 30 parts by mass causes insufficient impactresistance. The blending amount of titanium oxide is preferably 3 to 25parts by mass and more preferably 5 to 20 parts by mass relative to 100parts by mass of the thermoplastic resin. The mass of titanium oxidemeans the total mass of titanium oxide and alumina-based, silica-based,and organosiloxane-based surface-treating agents used forsurface-treating the titanium oxide.

7. Method for Producing Thermoplastic Resin Composition

A method for producing the thermoplastic resin composition according tothe third aspect of the present invention is not particularly limited.Various known methods for producing thermoplastic resin compositions canbe employed.

A specific example of the method is a method in which a thermoplasticresin, a fluoropolymer, a polycarbosilane compound serving as afluoropolymer dispersant, and a flame retardant and other components tobe optionally blended are mixed in advance, for example, in a mixer,such as a tumbler or a Henschel mixer, and are melt-kneaded in a mixer,such as a Banbury mixer, a roll, a Brabender, a single-screw extruder, atwin-screw extruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and then melt-kneaded to producethe thermoplastic resin composition according to the third aspect of thepresent invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and melt-kneaded to produce the thermoplastic resincomposition according to the third aspect of the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

8. Thermoplastic Resin Formed Product

The thermoplastic resin composition according to the third aspect of thepresent invention can generally be formed into thermoplastic resinformed products having any shape. The shape, design, color, and size ofthe formed products are not particularly limited and may beappropriately determined in accordance with each application of theformed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators; and members for near-infrared laser welding,and members for sensing devices, exemplified by various automobilesensing devices, such as face direction detection systems and rainsensors, various security systems, such as face recognition systems,fingerprint recognition systems, and vein recognition systems, andvarious information communication devices, such as remote controllersand infrared communication devices, in automobile, electrical andelectronic, and other precision apparatus fields.

A method for manufacturing formed products is not particularly limited.Any common molding method for thermoplastic resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies, afoam molding (including supercritical fluid) method, an insert moldingmethod, an IMC (in-mold coating molding) molding method, an extrusionmolding method, a sheet forming method, a thermoforming method, arotational molding method, a laminate molding method, and a pressforming method. A hot-runner molding method may also be used.

The thermoplastic resin formed product according to the third aspect ofthe present invention obtained by shaping the thermoplastic resincomposition according to the third aspect of the present invention hasmelt properties of the thermoplastic resin and surface properties, suchas sliding characteristics, scratch resistance, water repellency, oilrepellency, stain resistance, and fingerprint resistance, improved bythe blend of the fluoropolymer and furthermore has improved flameresistance, without adversely affecting the excellent intrinsiccharacteristics of thermoplastic resins. Thus, the thermoplastic resinformed product can be used as a practical formed product in a widevariety of applications.

IV. Fourth Aspect of the Present Invention 1. Overview

A polycarbonate resin composition according to the fourth aspect of thepresent invention contains at least a polycarbonate resin, a metal saltcompound, and a polysilane. The polycarbonate resin compositionaccording to the fourth aspect of the present invention may optionallycontain other components.

2. Polycarbonate Resin

There is no limitation on the type of polycarbonate resin used in thepolycarbonate resin composition according to the forth aspect of thepresent invention. Polycarbonate resins may be used alone, or two ormore polycarbonate resins may be combined with each other at any ratio.

Among these, the polycarbonate resin preferably contains a predeterminedpercentage of a polycarbonate resin having a structural viscosity indexN within a predetermined range.

The polycarbonate resin in the fourth aspect of the present invention isa polymer having a basic structure having a carbonate bond representedby the following formula (7).

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins may be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

In the fourth aspect of the present invention, the descriptions of [2-1.Dihydroxy Compound], [2-2. Carbonate Precursor], and [2-3. Method forProducing Polycarbonate Resin] in I. First Aspect of the PresentInvention can be applied to [2-1. Dihydroxy Compound], [2-2. CarbonatePrecursor], and [2-3. Method for Producing Polycarbonate Resin] of thepolycarbonate resin, respectively.

The polycarbonate resin in the fourth aspect of the present inventionpreferably contains 20% by mass or more of aromatic polycarbonate resinhaving a structural viscosity index N of 1.2 or more (predetermined Npolycarbonate resin). The descriptions of [2-4. Structural ViscosityIndex of Polycarbonate Resin] and [2-5. Method for ProducingPredetermined N Polycarbonate Resin] in II. Second Aspect of the PresentInvention can be applied to [2-4. Structural Viscosity Index ofPolycarbonate Resin] and [2-5. Method for Producing Predetermined NPolycarbonate Resin], respectively.

The description of [2-4. Other Matters regarding Polycarbonate Resin] inI. First Aspect of the Present Invention can be applied to [2-6. OtherMatters regarding Polycarbonate Resin] of the polycarbonate resin usedin the fourth aspect of the present invention.

3. Metal Salt Compound

The polycarbonate resin composition according to the fourth aspect ofthe present invention contains a metal salt compound. The metal saltcompound can improve the flame resistance of the polycarbonate resincomposition according to the fourth aspect of the present invention.

Alkali metals or alkaline-earth metals are preferred as metals of themetal salt compound. This is because they can promote the formation of acarbonized layer during the combustion of the polycarbonate resincomposition according to the fourth aspect of the present invention,thereby further improving flame resistance, and can maintain excellentmechanical properties, such as impact resistance, heat resistance, andelectrical characteristics of the polycarbonate resin. Thus, the metalsalt compound is preferably at least one metal salt compound selectedfrom the group consisting of alkali metal salts and alkaline-earth metalsalts and more preferably an alkali metal salt.

Examples of the metal salt compound include organic metal salt compoundsand inorganic metal salt compounds. In terms of dispersibility inpolycarbonate resins, organic metal salt compounds are preferred.

The description of [3. Metal Salt Compound] in II. Second Aspect of thePresent Invention can be applied to the metal salt compound used in thefourth aspect of the present invention.

The content of metal salt compound in the polycarbonate resincomposition according to the fourth aspect of the present invention is0.01 parts by mass or more, preferably 0.02 parts by mass or more, morepreferably 0.03 parts by mass or more, and particularly preferably 0.05parts by mass or more and 1 part by mass or less, preferably 0.75 partsby mass or less, more preferably 0.5 parts by mass or less, andparticularly preferably 0.3 parts by mass or less relative to 100 partsby mass of the polycarbonate resin. An excessively low content of metalsalt compound may result in insufficient flame resistance of theresultant polycarbonate resin composition. On the other hand, anexcessively high content of metal salt compound may result in reducedthermal stability of the polycarbonate resin and poor appearance and lowmechanical strength of a formed product.

4. Polysilane

The polycarbonate resin composition according to the fourth aspect ofthe present invention contains a polysilane. The polycarbonate resincomposition containing the polysilane can have high flowability.Furthermore, the combination of the polysilane and the metal saltcompound can significantly improve the flame resistance of thepolycarbonate resin composition according to the fourth aspect of thepresent invention. The detailed reason for the significant synergisticeffect of improving flame resistance achieved by combining the metalsalt compound is unclear. However, this is probably because the Si—Sibond of the polysilane is partially cleaved due to the catalytic actionof the metal salt compound at a temperature during combustion and thus acomposite of the polycarbonate resin and the polysilane is efficientlyformed.

Any polysilane may be used provided that the polysilane is a polymerhaving a Si—Si bond. The polysilane may have a linear, branched, cyclic,or network structure, but generally has at least one of the structuralunits represented by the following formulae (1) to (3).

In the formulae (1) to (3), R¹, R², and R³ each independently representa monovalent hydrocarbon group, a hydrogen atom, or a silyl group; a, b,and c each independently represent 0 or 1; and a plurality of R¹s, R²s,and R³s in the main chain structure may each be the same or different.

Examples of such a polysilane include linear or cyclic polysilaneshaving a structural unit represented by the formula (1), branched ornetwork polysilanes having a structural unit represented by the formula(2) or (3), and polysilanes having a combination of structural unitsrepresented by the formulae (1) to (3), for example, a combination ofthe formula (1) and the formula (2), the formula (1) and the formula(3), the formula (2) and the formula (3), or the formulae (1) to (3).Among these, linear polysilanes and cyclic polysilanes are preferredbecause they tend to have excellent dispersibility in polycarbonateresins. In particular, linear polysilanes are preferred because theytend to have high heat resistance. The linear polysilanes may partiallyhave a branched or network structure.

Specifically, the linear polysilanes having the structural unitrepresented by the formula (1) can be represented by the followingformula (4A), and the cyclic polysilanes having the structural unitrepresented by the formula (1) can be represented by the followingformula (4B).

In the formula (4A), R¹, R², a, and b are as defined in the formula (1);R³¹ and R³² each independently represent a monovalent hydrocarbon group,a hydrogen atom, or a silyl group; s and t each independently represent0 or 1; w represents an integer of 3 or more; and a plurality of R¹s andR²s in the main chain structure may each be the same or different.

In the formula (4B), R¹, R², a, and b are as defined in the formula (1);x represents an integer of 4 to 12; and a plurality of R¹s and R²s inthe main chain structure may each be the same or different.

In the formulae (1) to (3), (4A), and (4B), the groups R¹, R², and R³represent at least one selected from monovalent hydrocarbon groups, ahydrogen atom, and silyl groups. Examples of the monovalent hydrocarbongroups include alkyl groups, cycloalkyl groups, alkenyl groups,cycloalkenyl groups, alkynyl groups, aryl groups, and aralkyl groups.Among these, alkyl groups and aryl groups are preferred, alkyl groupsare more preferred, and a methyl group is still more preferred. Thesubstituents represented by R¹, R², and R³ in all the repeating unitsmay each be the same or different.

Examples of the alkyl groups include a methyl group, an ethyl group, apropyl group, an isopropyl group, a butyl group, a t-butyl group, apentyl group, a hexyl group, an octyl group, a decyl group, and adodecyl group. In general, alkyl groups having 1 to 12 carbon atoms arepreferred. Among these, alkyl groups having 1 to 6 carbon atoms, such asa methyl group, an ethyl group, a propyl group, an isopropyl group, abutyl group, a t-butyl group, a pentyl group, and a hexyl group arepreferred. A methyl group is particularly preferred.

Examples of the cycloalkyl groups include cycloalkyl groups having 5 to14 carbon atoms, such as a cyclopentyl group and a cyclohexyl group.Among these, cycloalkyl groups having 5 to 8 carbon atoms are preferred.

Examples of the alkenyl groups include alkenyl groups having 2 to 8carbon atoms, such as a vinyl group and an allyl group. Examples of thecycloalkenyl groups include cycloalkenyl groups having 5 to 12 carbonatoms, such as a cyclopentyl group and a cyclohexyl group.

Examples of the alkynyl groups include alkynyl groups having 2 to 8carbon atoms, such as an ethynyl group and a propynyl group, andarylalkynyls, such as an ethynylbenzene group.

Examples of the aryl groups include aryl groups having 6 to 20 carbonatoms, such as a phenyl group, a methylphenyl (or tolyl) group, adimethylphenyl (or xylyl) group, and a naphthyl group. Among these, arylgroups having 6 to 10 carbon atoms are preferred, and a phenyl group isparticularly preferred.

Examples of the aralkyl groups include aralkyl groups having 6 to 20carbon atoms, such as a benzyl group, a phenethyl group, and aphenylpropyl group. Among these, aralkyl groups having 6 to 10 carbonatoms are preferred, and a benzyl group is particularly preferred.

Examples of the silyl groups include silyl groups having 1 to 10 siliconatoms, such as a silyl group, a disilanyl group, and a trisilanyl group.Among these, silyl groups having 1 to 6 silicon atoms are preferred. Atleast one of hydrogen atoms of each of the silyl groups may besubstituted with a functional group, such as an alkyl group, an arylgroup, or an alkoxy group.

In the formulae (1), (4A), and (4B), substituents represented by R¹ andR² each independently preferably represent an alkyl group or an arylgroup and particularly preferably represent a methyl group.

The degree of polymerization of the polysilane, that is, the number ofthe structural units represented by the formulae (1) to (3) in thepolysilane is generally 2 or more, preferably 5 or more, and morepreferably 10 or more and generally 500 or less, preferably 400 or less,and more preferably 300 or less. A degree of polymerization of 1 or lessmeans a polysilane monomer, and therefore the heat resistance issignificantly deteriorated. In the form of a polycarbonate resincomposition, such a polysilane is not preferred because it is easilygasified (volatilized) and tends to cause mold fouling and reducemechanical properties and flame resistance. It is extremely difficult toproduce a polysilane having a degree of polymerization of more than 500and the dispersibility of such a polysilane in polycarbonate resins isextremely low, and therefore such a polysilane is not preferred.

The degree of polymerization of the linear polysilane in the formula(4A), that is, w is generally 3 or more, preferably 5 or more, and morepreferably 7 or more and generally 300 or less, preferably 100 or less,more preferably 50 or less, and more preferably 30 or less. This rangeis preferred for the same reason as described above.

The degree of polymerization of the cyclic polysilane in the formula(4B), that is, x is generally 4 or more and preferably 5 or more andgenerally 12 or less, preferably 10 or less, and more preferably 8 orless. In particular, x is preferably about 5. A cyclic polysilane havingan x of 3 or less is difficult to produce due to its chemical structure.A cyclic polysilane having an x of 13 or more is also difficult toproduce.

In the formulae (1) to (3), (4A), and (4B), a, b, c, s, and t represent0 or 1. When each of a, b, c, s, and t is 0, the polysilane has an alkylgroup, a cycloalkyl group, an alkenyl group, a cycloalkenyl group, analkynyl group, an aryl group, an aralkyl group, a hydrogen atom, or asilyl group as an organic functional group. When each of a, b, c, s, andt is 1, the polysilane has an alkoxy group, a cycloalkyloxy group, analkenyloxy group, a cycloalkenyloxy group, an alkynyloxy group, anaryloxy group, an aralkyloxy group, or a hydroxyl group as an organicfunctional group. Although each of a, b, c, s, and t is preferably 0 interms of the heat resistance of the polysilane, each of a, b, c, s, andt may intentionally be 1 to improve an affinity for resins orunintentionally be 1 by oxidation or other actions.

In the case where the polysilane has an acyclic structure (linear,branched, or network), the terminal substituent is generally a hydrogenatom, a hydroxyl group, an alkyl group, an alkoxy group, or a silylgroup.

Examples of the polysilane include polydialkylsilanes, such aspolydimethylpolysilane, polymethylpropylsilane, polymethylbutylsilane,polymethylpentylsilane, polydibutylsilane, polydihexylsilane, and adimethylsilane-methylhexylsilane copolymer; polyalkylarylsilanes, suchas polymethylphenylsilane and a methylphenylsilane-phenylhexylsilanecopolymer; polydiarylsilanes, such as polydiphenylsilane; anddialkylsilane-alkylarylsilane copolymers, such as adimethylsilane-methylphenylsilane copolymer, adimethylsilane-phenylhexylsilane copolymer, and adimethylsilane-methylnaphthylsilane copolymer. The details of suchpolysilanes are described in, for example, R. D. Miller, J. Michl,Chemical Review, 89, 1359 (1989), and N. Matsumoto, Japanese Journal ofPhysics, 37, 5425 (1998).

The molecular weight of the polysilane is generally 300 or more,preferably 400 or more, and more preferably 500 or more and generally200000 or less, preferably 100000 or less, more preferably 50000 orless, and still more preferably 10000 or less, on a basis ofnumber-average molecular weight. A polysilane having a number-averagemolecular weight of less than 300 unfavorably has low heat resistance,which may result in reduced flame resistance of the polycarbonate resincomposition. A polysilane having a number-average molecular weight ofmore than 200000 unfavorably has extremely low dispersibility in andcompatibility with polycarbonate resins, which may result in reducedmechanical properties and flame resistance.

Any known method may be appropriately used as a method for producing thepolysilane according to the fourth aspect of the present invention.Examples of the method include a method in which a silicon-containingmonomer having a certain structural unit is prepared as a raw material,and dehalogenation condensation polymerization is performed onhalosilanes using magnesium as a reducing agent (magnesium reductionmethod); a method in which dehalogenation condensation polymerization isperformed on halosilanes in the presence of an alkali metal (cappingmethod); a method in which dehalogenation condensation polymerization isperformed on halosilanes by electrode reduction; a method in whichdehalogenation condensation polymerization is performed on halosilanesby electrode reduction; a method in which dehydrogenation condensationpolymerization is performed on hydrazines in the presence of a metalcatalyst; a method in which anionic polymerization is performed ondisilenes crosslinked with biphenyl or the like; and a method in whichring-opening polymerization is performed on cyclic silanes. Among thesemethods, the magnesium reduction method is particularly preferred inconsideration of ease of control of the purity, molecular weightdistribution, and content of impurities, such as sodium and chlorine, ofthe polysilane to be produced and also in consideration of industrialadvantages in terms of production cost and safety. Water may be added tothe resultant polysilane to generate a silanol group.

The content of the polysilane in the polycarbonate resin compositionaccording to the fourth aspect of the present invention is 0.01 parts bymass or more, preferably 0.025 parts by mass or more, more preferably0.05 parts by mass or more, and particularly preferably 0.1 parts bymass or more and 5 parts by mass or less, preferably 3 parts by mass orless, more preferably 2.5 parts by mass or less, and particularlypreferably 1 part by mass or less relative to 100 parts by mass of thepolycarbonate resin. An excessively low content of polysilane may resultin insufficient flame resistance of the resultant polycarbonate resincomposition. On the other hand, at an excessively high content ofpolysilane, its effect may be leveled off and thus its use may beuneconomical. In addition, such an excessively high content ofpolysilane may result in reduced thermal stability of the polycarbonateresin and poor appearance and low mechanical strength of a formedproduct. Polysilanes may be used alone or in combination.

5. Other Components

The polycarbonate resin composition according to the fourth aspect ofthe present invention may optionally contain components other than thosedescribed above provided that desired physical properties are notsignificantly deteriorated. Examples of the other components includeresins other than polycarbonate resins and various resin additiveagents. The other components may be contained alone, or two or more ofthe other components may be contained at any ratio.

The description of <Other Resins> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to <Other Resins> that may be containedin the polycarbonate resin composition according to the fourth aspect ofthe present invention.

<Resin Additive Agents>

Examples of the resin additive agents include a heat stabilizer, anantioxidant, a mold-release agent, an ultraviolet absorber, a dye orpigment, a flame retardant, an anti-dripping agent, an antistatic agent,an anti-fogging agent, a lubricant, an anti-blocking agent, a flowmodifier, a sliding modifier, a plasticizer, a dispersant, and anantimicrobial agent. The resin additive agents may be contained alone,or two or more of the resin additive agents may be contained at anyratio.

The descriptions of (Heat Stabilizer), (Antioxidant), (Mold-ReleaseAgent), (Ultraviolet Absorber), (Dye or Pigment), and (Anti-DrippingAgent) of <Resin Additive Agents> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to exemplary resin additive agents(Heat Stabilizer), (Antioxidant), (Mold-Release Agent), (UltravioletAbsorber), (Dye or Pigment), and (Anti-Dripping Agent) suitable for thepolycarbonate resin composition according to the fourth aspect of thepresent invention.

6. Method for Producing Polycarbonate Resin Composition

A method for producing the polycarbonate resin composition according tothe fourth aspect of the present invention is not particularly limited.Various known methods for producing polycarbonate resin compositions canbe employed.

A specific example is a method in which the polycarbonate resinaccording to the fourth aspect of the present invention, a metal saltcompound, a polysilane, and other components to be optionally blendedare mixed in advance, for example, in a mixer, such as a tumbler or aHenschel mixer, and are melt-kneaded in a mixer, such as a Banburymixer, a roll, a Brabender, a single-screw extruder, a twin-screwextruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and are melt-kneaded to producethe polycarbonate resin composition according to the fourth aspect ofthe present invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and is melt-kneaded to produce the polycarbonate resincomposition according to the fourth aspect of the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

7. Polycarbonate Resin Formed Product

The polycarbonate resin composition according to the fourth aspect ofthe present invention is generally formed into polycarbonate resinformed products having any shape. The shape, design, color, and size ofthe formed products are not particularly limited and may beappropriately determined in accordance with each application of theformed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators. Among these, the formed products aresuitably used for components of electrical and electronic devices, OAequipment, information terminals, and household electrical appliancesand are particularly suitably used for components of electrical andelectronic devices.

Examples of the electrical and electronic devices include personalcomputers, game machines, display units, such as television sets,printers, copying machines, scanners, facsimiles, electronic notebooksand PDAs, electronic calculators, electronic dictionaries, cameras,video cameras, cellular phones, battery packs, recording medium drivesand readers, mouses, numeric keypads, CD players, MD players, andportable radios and audio-players.

A method for manufacturing formed products is not particularly limited.Any common molding method for polycarbonate resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies,foam molding (including supercritical fluid), insert molding, an IMC(in-mold coating molding) molding method, an extrusion molding method, asheet forming method, a thermoforming method, a rotational moldingmethod, a laminate molding method, and a press forming method. Ahot-runner molding method may also be used.

As described above, the polycarbonate resin formed product according tothe fourth aspect of the present invention can be used as a practicalformed product having high scratch resistance, without impairingexcellent characteristics of polycarbonate resins.

V. Fifth Aspect of the Present Invention 1. Overview

The polycarbonate resin composition according to the fifth aspect of thepresent invention contains at least a polycarbonate resin, a metal saltcompound, a fluoropolymer, and a polysilane. The polycarbonate resincomposition according to the fifth aspect of the present invention mayoptionally contain other components.

2. Polycarbonate Resin

There is no limitation on the type of polycarbonate resin used in thepolycarbonate resin composition according to the fifth aspect of thepresent invention. Polycarbonate resins may be used alone, or two ormore polycarbonate resins may be combined with each other at any ratio.

The polycarbonate resin in the fifth aspect of the present invention isa polymer having a basic structure having a carbonate bond representedby the following formula (7).

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins may be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

In the fifth aspect of the present invention, the descriptions of [2-1.Dihydroxy Compound], [2-2. Carbonate Precursor], and [2-3. Method forProducing Polycarbonate Resin] in I. First Aspect of the PresentInvention can be applied to [2-1. Dihydroxy Compound], [2-2. CarbonatePrecursor], and [2-3. Method for Producing Polycarbonate Resin] of thepolycarbonate resin, respectively.

The polycarbonate resin in the fifth aspect of the present invention maybe a polycarbonate resin having a branched structure. A polycarbonateresin having a branched structure (hereinafter sometimes referred to asa “branched polycarbonate resin”) can be contained in order to suppressthe dripping during the combustion of the polycarbonate resincomposition according to the fifth aspect of the present invention andimprove the flame resistance.

The description of the method for producing a branched polycarbonateresin in [2-5. Method for Producing Predetermined N Polycarbonate Resin]in II. Second Aspect of the Present Invention can be applied to a methodfor producing a branched polycarbonate resin.

The description of [2-4. Other Matters regarding Polycarbonate Resin] inI. First Aspect of the Present Invention can be applied to [2-4. OtherMatters regarding Polycarbonate Resin] of the polycarbonate resin usedin the fifth aspect of the present invention.

3. Metal Salt Compound

The polycarbonate resin composition according to the fifth aspect of thepresent invention contains a metal salt compound. The metal saltcompound can improve the flame resistance of the polycarbonate resincomposition according to the fifth aspect of the present invention.

Examples of the metal of the metal salt compound include alkali metals,such as lithium (Li), sodium (Na), potassium (K), rubidium (Rb), andcesium (Cs); alkaline-earth metals, such as magnesium (Mg), calcium(Ca), strontium (Sr), and barium (Ba); and aluminum (Al), titanium (Ti),iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), zirconium(Zr), and molybdenum (Mo). Among these, alkali metals and alkaline-earthmetals are preferred. This is because they can promote the formation ofa carbonized layer during the combustion of the polycarbonate resincomposition according to the fifth aspect of the present invention,thereby improving flame resistance, and can maintain excellentmechanical properties, such as impact resistance, heat resistance, andelectrical characteristics of the polycarbonate resin. Thus, the metalsalt compound is more preferably at least one metal salt compoundselected from the group consisting of alkali metal salts andalkaline-earth metal salts, still more preferably an alkali metal salt,and particularly preferably sodium, potassium, or cesium.

Examples of the metal salt compound include organic metal salt compoundsand inorganic metal salt compounds. In terms of dispersibility inpolycarbonate resins, organic metal salt compounds are preferred.

The description of [3. Metal Salt Compound] in II. Second Aspect of thePresent Invention can be applied to the metal salt compound used in thefifth aspect of the present invention.

The content of the metal salt compound in the polycarbonate resincomposition according to the fifth aspect of the present invention is0.001 parts by mass or more, preferably 0.005 parts by mass or more,more preferably 0.01 parts by mass or more, and particularly preferably0.05 parts by mass or more and 1 part by mass or less, preferably 0.75parts by mass or less, more preferably 0.5 parts by mass or less, andparticularly preferably 0.3 parts by mass or less relative to 100 partsby mass of the polycarbonate resin. An excessively low content of metalsalt compound may result in insufficient flame resistance of theresultant polycarbonate resin composition. On the other hand, anexcessively high content of metal salt compound may result in reducedthermal stability of the polycarbonate resin and poor appearance and lowmechanical strength of a formed product.

4. Fluoropolymer

There is no limitation on the type of fluoropolymer used in thepolycarbonate resin composition according to the fifth aspect of thepresent invention. Fluoropolymers may be used alone, or two or morefluoropolymers may be combined with each other at any ratio.

The description of [3. Fluoropolymer] in III. Third Aspect of thePresent Invention can be applied to the fluoropolymer used in the fifthaspect of the present invention.

In the fifth aspect of the present invention, the content of thefluoropolymer is generally 0.001 parts by mass or more, preferably 0.005parts by mass or more, more preferably 0.01 parts by mass or more, andparticularly preferably 0.05 parts by mass or more and generally 1 partby mass or less, preferably 0.7 parts by mass or less, and morepreferably 0.5 parts by mass or less relative to 100 parts by mass ofthe polycarbonate resin. A fluoropolymer content less than or equal tothe lower limit may result in insufficient flame resistant effectsproduced by the fluoropolymer. A fluoropolymer content more than theupper limit may result in poor appearance and low mechanical strength offormed products obtained by shaping the polycarbonate resin composition.

5. Polysilane

The polycarbonate resin composition according to the fifth aspect of thepresent invention contains a polysilane. The simultaneous inclusion ofthe polysilane and the metal salt compound can markedly improve theflame resistance of the polycarbonate resin composition according to thefifth aspect of the present invention. The detailed reason for thesignificant synergistic effect of improving flame resistance achieved bycombining the metal salt compound is unclear. However, this is probablybecause the Si—Si bond of the polysilane is partially cleaved due to thecatalytic action of the metal salt compound at a temperature duringcombustion and thus a composite of the polycarbonate resin and thepolysilane is efficiently formed to form a crosslinked structure, whichresults in an improvement in anti-dripping properties during combustion.

The description of [4. Polysilane] in IV. Fourth Aspect of the PresentInvention can be applied to the polysilane used in the fifth aspect ofthe present invention.

The content of the polysilane in the polycarbonate resin compositionaccording to the fifth aspect of the present invention is 0.01 parts bymass or more, preferably 0.015 parts by mass or more, and morepreferably 0.02 parts by mass or more and 2 parts by mass or less,preferably 1.5 parts by mass or less, and more preferably 1 part by massor less relative to 100 parts by mass of the polycarbonate resin. Anexcessively low content of polysilane may result in insufficient flameresistance of the resultant polycarbonate resin composition. On theother hand, an excessively high content of polysilane may result inreduced flame resistance or mechanical strength of the polycarbonateresin. Polysilanes may be used alone or in combination.

6. Other Components

The polycarbonate resin composition according to the fifth aspect of thepresent invention may optionally contain components other than thosedescribed above provided that desired physical properties are notsignificantly deteriorated. Examples of the other components includeresins other than polycarbonate resins and various resin additiveagents. The other components may be contained alone, or two or more ofthe other components may be contained at any ratio.

The description of <Other Resins> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to <Other Resins> that may be containedin the polycarbonate resin composition according to the fifth aspect ofthe present invention.

<Resin Additive Agents>

Examples of the resin additive agents include a heat stabilizer, anantioxidant, a mold-release agent, an ultraviolet absorber, a dye orpigment, a fibrous reinforcement, an optical function regulator, a flameretardant, an anti-dripping agent, an antistatic agent, an anti-foggingagent, a lubricant, an anti-blocking agent, a flow modifier, a slidingmodifier, a plasticizer, a dispersant, and an antimicrobial agent. Theresin additive agents may be contained alone, or two or more of theresin additive agents may be contained at any ratio.

The descriptions of Heat Stabilizer, Antioxidant, Mold-Release Agent,Ultraviolet Absorber, and Dye or Pigment of <Resin Additive Agents> thatmay be contained in the polycarbonate resin composition according to I.First Aspect of the Present Invention can be applied to exemplary resinadditive agents Heat Stabilizer, Antioxidant, Mold-Release Agent,Ultraviolet Absorber, and Dye or Pigment suitable for the polycarbonateresin composition according to the fifth aspect of the presentinvention, respectively.

Regarding Fibrous Reinforcement and Optical Function Regulator, thedescriptions of Fibrous Reinforcement and Optical Function Regulator of<Resin Additive Agents> that may be contained in the thermoplastic resincomposition according to III. Third Aspect of the Present Invention canbe applied respectively. Their amounts to be blended may be determinedby replacing the thermoplastic resin in the thermoplastic resincomposition with the polycarbonate resin in the polycarbonate resincomposition.

7. Method for Producing Polycarbonate Resin Composition

A method for producing the polycarbonate resin composition according tothe fifth aspect of the present invention is not particularly limited.Various known methods for producing polycarbonate resin compositions canbe employed.

A specific example is a method in which the polycarbonate resinaccording to the fifth aspect of the present invention, a metal saltcompound, a fluoropolymer, a polysilane, and other components to beoptionally blended are mixed in advance, for example, in a mixer, suchas a tumbler or a Henschel mixer, and are melt-kneaded in a mixer, suchas a Banbury mixer, a roll, a Brabender, a single-screw extruder, atwin-screw extruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and are melt-kneaded to producethe polycarbonate resin composition according to the fifth aspect of thepresent invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and is melt-kneaded to produce the polycarbonate resincomposition according to the fifth aspect of the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

8. Polycarbonate Resin Formed Product

The polycarbonate resin composition according to the fifth aspect of thepresent invention is generally formed into polycarbonate resin formedproducts having any shape. The shape, design, color, and size of theformed products are not particularly limited and may be appropriatelydetermined in accordance with each application of the formed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators. Among these, the formed products aresuitably used for components of electrical and electronic devices, OAequipment, information terminals, household electrical appliances, andilluminators and are particularly suitably used for components ofelectrical and electronic devices.

Examples of the electrical and electronic devices include personalcomputers, game machines, display units, such as television sets,printers, copying machines, scanners, facsimiles, electronic notebooksand PDAs, electronic calculators, electronic dictionaries, cameras,video cameras, cellular phones, battery packs, recording medium drivesand readers, mouses, numeric keypads, CD players, MD players, andportable radios and audio-players.

A method for manufacturing formed products is not particularly limited.Any common molding method for polycarbonate resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies,foam molding (including supercritical fluid), insert molding, an IMC(in-mold coating molding) molding method, an extrusion molding method, asheet forming method, a thermoforming method, a rotational moldingmethod, a laminate molding method, and a press forming method. Ahot-runner molding method may also be used.

As described above, the polycarbonate resin formed product according tothe fifth aspect of the present invention can be used as a practicalformed product having high flame resistance and excellent mechanicalproperties, without impairing excellent characteristics of polycarbonateresins.

VI. Sixth Aspect of the Present Invention 1. Overview

A polycarbonate resin composition according to a sixth aspect of thepresent invention contains at least a polycarbonate resin, a metal saltcompound, and a polysilane having an aryl group. The polycarbonate resincomposition according to the sixth aspect of the present invention mayoptionally contain other components.

2. Polycarbonate Resin

There is no limitation on the type of polycarbonate resin used in thepolycarbonate resin composition according to the sixth aspect of thepresent invention. Polycarbonate resins may be used alone, or two ormore polycarbonate resins may be combined with each other at any ratio.

The polycarbonate resin in the sixth aspect of the present invention isa polymer having a basic structure having a carbonate bond representedby the following formula (7).

In the formula (7), X¹ generally represents a hydrocarbon group, and X¹containing a heteroatom or a hetero bond for imparting variouscharacteristics may be used.

Polycarbonate resins can be classified into aromatic polycarbonateresins in which each carbon directly bonded to the carbonate bond isaromatic carbon and aliphatic polycarbonate resins in which each carbondirectly bonded to the carbonate bond is aliphatic carbon. Both aromaticpolycarbonate resins and aliphatic polycarbonate resins may be used.Aromatic polycarbonate resins are preferred in terms of heat resistance,mechanical properties, and electrical characteristics.

The type of polycarbonate resin is not particularly limited. One exampleis a polycarbonate polymer produced through the reaction between adihydroxy compound and a carbonate precursor. In addition to thedihydroxy compound and the carbonate precursor, a polyhydroxy compoundmay be involved in the reaction. Alternatively, carbon dioxide may beused as the carbonate precursor to react with a cyclic ether. Thepolycarbonate polymer may have a straight chain or a branched chain. Thepolycarbonate polymer may be a homopolymer composed of one repeatingunit or a copolymer composed of two or more repeating units. Thecopolymer may be selected from various copolymerization forms, such as arandom copolymer and a block copolymer. In general, such polycarbonatepolymers are thermoplastic resins.

In the sixth aspect of the present invention, the descriptions of [2-1.Dihydroxy Compound], [2-2. Carbonate Precursor], and [2-3. Method forProducing Polycarbonate Resin] in I. First Aspect of the PresentInvention can be applied to [2-1. Dihydroxy Compound], [2-2. CarbonatePrecursor], and [2-3. Method for Producing Polycarbonate Resin] of thepolycarbonate resin, respectively.

The polycarbonate resin in the sixth aspect of the present inventionpreferably contains 20% by mass or more of aromatic polycarbonate resinhaving a structural viscosity index N of 1.2 or more (predetermined Npolycarbonate resin). The descriptions of [2-4. Structural ViscosityIndex of Polycarbonate Resin] and [2-5. Method for ProducingPredetermined N Polycarbonate Resin] in II. Second Aspect of the PresentInvention can be applied to [2-4. Structural Viscosity Index ofPolycarbonate Resin] and [2-5. Method for Producing Predetermined NPolycarbonate Resin], respectively.

The description of [2-4. Other Matters regarding Polycarbonate Resin] inI. First Aspect of the Present Invention can be applied to [2-6. OtherMatters regarding Polycarbonate Resin] of the polycarbonate resin usedin the sixth aspect of the present invention.

3. Metal Salt Compound

The polycarbonate resin composition according to the sixth aspect of thepresent invention contains a metal salt compound. The metal saltcompound can improve the flame resistance of the polycarbonate resincomposition according to the sixth aspect of the present invention.

The type of metal of the metal salt compound is preferably an alkalimetal or an alkaline-earth metal. This is because they can promote theformation of a carbonized layer during the combustion of thepolycarbonate resin composition according to the sixth aspect of thepresent invention, thereby improving flame resistance, and can maintainexcellent mechanical properties, such as impact resistance, heatresistance, and electrical characteristics of the polycarbonate resin.Thus, the metal salt compound is preferably at least one metal saltcompound selected from the group consisting of alkali metal salts andalkaline-earth metal salts and more preferably an alkali metal salt.

Examples of the metal salt compound include organic metal salt compoundsand inorganic metal salt compounds. In terms of dispersibility inpolycarbonate resins, organic metal salt compounds are preferred.

The description of [3. Metal Salt Compound] in II. Second Aspect of thePresent Invention can be applied to the metal salt compound used in thesixth aspect of the present invention.

The content of the metal salt compound in the polycarbonate resincomposition according to the sixth aspect of the present invention is0.01 parts by mass or more, preferably 0.02 parts by mass or more, morepreferably 0.03 parts by mass or more, and particularly preferably 0.05parts by mass or more and 1 part by mass or less, preferably 0.75 partsby mass or less, more preferably 0.5 parts by mass or less, andparticularly preferably 0.3 parts by mass or less relative to 100 partsby mass of the polycarbonate resin. An excessively low content of metalsalt compound may result in insufficient flame resistance of theresultant polycarbonate resin composition. On the other hand, anexcessively high content of metal salt compound may result in reducedthermal stability of the polycarbonate resin and poor appearance and lowmechanical strength of a formed product.

4. Polysilane Having Aryl Group

The polycarbonate resin composition according to the sixth aspect of thepresent invention contains a polysilane having an aryl group. Thesimultaneous inclusion of the polysilane having an aryl group and themetal salt compound can markedly improve the flame resistance of thepolycarbonate resin composition according to the sixth aspect of thepresent invention. The detailed reason for the significant synergisticeffect of improving flame resistance achieved by combining the metalsalt compound is unclear. However, this is probably because the Si—Sibond of the polysilane is partially cleaved due to the catalytic actionof the metal salt compound at a temperature during combustion and thus acomposite of the polycarbonate resin and the polysilane is efficientlyformed.

When a polysilane has an aryl group, the heat resistance of thepolysilane itself is increased and the compatibility with anddispersibility in polycarbonate resins are improved. Thus, apolycarbonate resin composition having high transparency and impactresistance is believed to be obtained.

Any polysilane having an aryl group may be used provided that thepolysilane is a polymer having an aryl group in the molecule as anessential substituent and a Si—Si bond. Such a polysilane may have alinear, branched, cyclic, or network structure and generally has atleast one of the structural units represented by the following formulae(1) to (3).

In the formulae (1) to (3), R¹, R², and R³ each independently representa monovalent hydrocarbon group, a hydrogen atom, or a silyl group; a, b,and c each independently represent 0 or 1; and a plurality of R¹s, R²s,and R³s in the main chain structure may each be the same or different,provided that at least one of the R¹s, R²s, and R³s in the main chainstructure has an aryl group.

Examples of such a polysilane having an aryl group include linear orcyclic polysilanes having an aryl group and a structural unitrepresented by the formula (1), branched or network polysilanes havingan aryl group and a structural unit represented by the formula (2) or(3), and polysilanes having an aryl group and a combination ofstructural units represented by the formulae (1) to (3), for example, acombination of the formula (1) and the formula (2), the formula (1) andthe formula (3), the formula (2) and the formula (3), or the formulae(1) to (3). Among these, linear polysilanes having an aryl group andcyclic polysilanes having an aryl group are preferred because they tendto have high dispersibility in polycarbonate resins. In particular,cyclic polysilanes having an aryl group are preferred because they tendto have high dispersibility in polycarbonate resins.

Specifically, such a cyclic polysilane having an aryl group and astructural unit represented by the formula (1) can also be representedby the following formula (4B).

In the formula (4B), R¹, R², a, and b are as defined in the formula (1);x represents an integer of 4 to 12; and a plurality of R¹s and R²s inthe main chain structure may each be the same or different, providedthat at least one of the plurality of R¹s and R²s in the main chainstructure has an aryl group.

In the formulae (1) to (3) and (4B), the groups R¹, R², and R³ representat least one selected from monovalent hydrocarbon groups, a hydrogenatom, and silyl groups. Examples of the monovalent hydrocarbon groupsinclude alkyl groups, cycloalkyl groups, alkenyl groups, cycloalkenylgroups, alkynyl groups, aryl groups, and aralkyl groups. Among these,alkyl groups and aryl groups are preferred, aryl groups are morepreferred, and a phenyl group is still more preferred. The substituentsrepresented by R¹, R², and R³ in all the repeating units may each be thesame or different.

Examples of the alkyl groups include a methyl group, an ethyl group, apropyl group, an isopropyl group, a butyl group, a t-butyl group, apentyl group, a hexyl group, an octyl group, a decyl group, and adodecyl group. In general, alkyl groups having 1 to 12 carbon atoms arepreferred. Among these, alkyl groups having 1 to 6 carbon atoms, such asa methyl group, an ethyl group, a propyl group, an isopropyl group, abutyl group, a t-butyl group, a pentyl group, and a hexyl group arepreferred. A methyl group is particularly preferred.

Examples of the cycloalkyl groups include cycloalkyl groups having 5 to14 carbon atoms, such as a cyclopentyl group and a cyclohexyl group.Among these, cycloalkyl groups having 5 to 8 carbon atoms are preferred.

Examples of the alkenyl groups include alkenyl groups having 2 to 8carbon atoms, such as a vinyl group and an allyl group. Examples of thecycloalkenyl groups include cycloalkenyl groups having 5 to 12 carbonatoms, such as a cyclopentyl group and a cyclohexyl group.

Examples of the alkynyl groups include alkynyl groups having 2 to 8carbon atoms, such as an ethynyl group and a propynyl group, andarylalkynyls, such as an ethynylbenzene group.

Examples of the aryl groups include aryl groups having 6 to 20 carbonatoms, such as a phenyl group, a methylphenyl (or tolyl) group, adimethylphenyl (or xylyl) group, and a naphthyl group. Among these, arylgroups having 6 to 10 carbon atoms are preferred, and a phenyl group isparticularly preferred.

Examples of the aralkyl groups include aralkyl groups having 6 to 20carbon atoms, such as a benzyl group, a phenethyl group, and aphenylpropyl group. Among these, aralkyl groups having 6 to 10 carbonatoms are preferred, and a benzyl group is particularly preferred.

Examples of the silyl groups include silyl groups having 1 to 10 siliconatoms, such as a silyl group, a disilanyl group, and a trisilanyl group.Among these, silyl groups having 1 to 6 silicon atoms are preferred. Atleast one of hydrogen atoms of each of the silyl groups may besubstituted with a functional group, such as an alkyl group, an arylgroup, or an alkoxy group.

Each of the substituents R¹ and R² in the formulae (1) and (4B) isparticularly preferably a phenyl group.

The degree of polymerization of the polysilane having an aryl group,that is, the number of the structural units represented by the formulae(1) to (3) in the polysilane having an aryl group is generally 2 ormore, preferably 3 or more, and more preferably 4 or more and generally500 or less, preferably 400 or less, and more preferably 300 or less. Adegree of polymerization of 1 or less means a polysilane monomer, andtherefore the heat resistance is significantly deteriorated. In the formof a polycarbonate resin composition, such a polysilane is not preferredbecause it is easily gasified (volatilized) and tends to cause moldfouling and reduce mechanical properties and flame resistance. It isextremely difficult to produce a polysilane having a degree ofpolymerization of more than 500 and the dispersibility of such apolysilane in polycarbonate resins is extremely low, and therefore sucha polysilane is not preferred.

The degree of polymerization of the cyclic polysilane having an arylgroup in the formula (4B), that is, x is generally 4 or more andpreferably 5 or more and generally 12 or less, preferably 10 or less,and more preferably 8 or less. In particular, x is preferably 5. Acyclic polysilane having an aryl group and an x of 3 or less isdifficult to produce due to its chemical structure. A cyclic polysilanehaving an aryl group and an x of more than 12 is also difficult toproduce.

In the formulae (1) to (3) and (4B), a, b, and c represent 0 or 1. Wheneach of a, b, and c is 0, the polysilane having an aryl group has analkyl group, a cycloalkyl group, an alkenyl group, a cycloalkenyl group,an alkynyl group, an aryl group, an aralkyl group, a hydrogen atom, or asilyl group as an organic functional group. When each of a, b, and c is1, the polysilane has an alkoxy group, a cycloalkyloxy group, analkenyloxy group, a cycloalkenyloxy group, an alkynyloxy group, anaryloxy group, an aralkyloxy group, or a hydroxyl group as an organicfunctional group. Although each of a, b, and c is preferably 0 in termsof the heat resistance of the polysilane having an aryl group, each ofa, b, and c may intentionally be 1 to improve an affinity for resins orunintentionally be 1 by oxidation or other actions.

In the case where the polysilane having an aryl group has an acyclicstructure (linear, branched, or network), the terminal substituent isgenerally a hydrogen atom, a hydroxyl group, an alkyl group, an alkoxygroup, or a silyl group.

Examples of the polysilane having an aryl group include linear,branched, or network polysilanes having an aryl group, for example,polyalkylarylsilanes, such as polymethylphenylsilane and amethylphenylsilane-phenylhexylsilane copolymer; polydiarylsilanes, suchas polydiphenylsilane; and dialkylsilane-alkylarylsilane copolymers,such as a dimethylsilane-methylphenylsilane copolymer, adimethylsilane-phenylhexylsilane copolymer, and adimethylsilane-methylnaphthylsilane copolymer; and cyclic polysilaneshaving an aryl group, for example, cyclic alkylarylsilanes, such asmethylphenylcyclosilane, and cyclic arylsilanes, such asdiphenylcyclosilane.

The details of such polysilanes having an aryl group are described in,for example, R. D. Miller, J. Michl, Chemical Review, 89, 1359 (1989),and N. Matsumoto, Japanese Journal of Physics, 37, 5425 (1998).

The polysilane having an aryl group according to the sixth aspect of thepresent invention is particularly preferably a cyclic polysilane havingan aryl group and more preferably a cyclic arylsilane. Specific examplesof the cyclic arylsilane include octaphenylcyclotetrasilane,decaphenylcyclopentasilane, and dodecaphenylcyclohexasilane. Amongthese, decaphenylcyclopentasilane is particularly preferred.

Such a cyclic polysilane having an aryl group markedly improve thecompatibility with and dispersibility in polycarbonate resins and thus apolycarbonate resin composition having excellent flame resistance,transparency, hue, and impact resistance tends to be obtained.

The molecular weight of the polysilane having an aryl group according tothe sixth aspect of the present invention is generally 300 or more,preferably 350 or more, and more preferably 400 or more and generally200000 or less, preferably 50000 or less, more preferably 10000 or less,still more preferably 5000 or less, and most preferably 2000 or less, ona basis of number-average molecular weight [Mn]. A polysilane having anumber-average molecular weight of less than 300 unfavorably has lowheat resistance, which may result in reduced flame resistance of thepolycarbonate resin composition and mold fouling during shapeprocessing. A polysilane having a number-average molecular weight ofmore than 200000 unfavorably has extremely low dispersibility in andcompatibility with polycarbonate resins, which may result in reducedmechanical properties and flame resistance.

The number-average molecular weight [Mn] of the polysilane having anaryl group is a polystyrene equivalent value measured by gel permeationchromatography (GPC) at a temperature of 40° C. using tetrahydrofuran asa solvent.

Any known method may be appropriately used as a method for producing thepolysilane having an aryl group according to the sixth aspect of thepresent invention. Examples of the method include a method in which asilicon-containing monomer having a certain structural unit is preparedas a raw material, and dehalogenation condensation polymerization isperformed on halosilanes using magnesium as a reducing agent (magnesiumreduction method); a method in which dehalogenation condensationpolymerization is performed on halosilanes in the presence of an alkalimetal (capping method); a method in which dehalogenation condensationpolymerization is performed on halosilanes by electrode reduction; amethod in which dehalogenation condensation polymerization is performedon halosilanes by electrode reduction; a method in which dehydrogenationcondensation polymerization is performed on hydrazines in the presenceof a metal catalyst; a method in which anionic polymerization isperformed on disilenes crosslinked with biphenyl or the like; and amethod in which ring-opening polymerization is performed on cyclicsilanes. Among these methods, the magnesium reduction method isparticularly preferred in consideration of ease of control of thepurity, molecular weight distribution, and content of impurities, suchas sodium and chlorine, of the polysilane having an aryl group to beproduced and also in consideration of industrial advantages in terms ofproduction cost and safety. Water may be added to the resultantpolysilane having an aryl group to generate a silanol group.

The content of the polysilane having an aryl group in the polycarbonateresin composition according to the sixth aspect of the present inventionis 0.3 parts by mass or more, preferably 0.4 parts by mass or more, morepreferably 0.5 parts by mass or more, and particularly preferably 0.75parts by mass or more and 5 parts by mass or less, preferably 4 parts bymass or less, more preferably 3 parts by mass or less, and particularlypreferably 2 parts by mass or less relative to 100 parts by mass of thepolycarbonate resin. An excessively low content of polysilane may resultin insufficient flame resistance of the resultant polycarbonate resincomposition. On the other hand, at an excessively high content ofpolysilane, its effect may be leveled off and thus its use may beuneconomical. In addition, such an excessively high content ofpolysilane may result in reduced transparency and impact resistance ofthe polycarbonate resin and poor appearance and low mechanical strengthof a formed product. Polysilanes having an aryl group may be used aloneor in combination.

5. Other Components

The polycarbonate resin composition according to the sixth aspect of thepresent invention may optionally contain components other than thosedescribed above provided that desired physical properties are notsignificantly deteriorated. Examples of the other components includeresins other than polycarbonate resins and various resin additiveagents. The other components may be contained alone, or two or more ofthe other components may be contained at any ratio.

The description of <Other Resins> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to <Other Resins> that may be containedin the polycarbonate resin composition according to the sixth aspect ofthe present invention.

<Resin Additive Agents>

Examples of the resin additive agents include a heat stabilizer, anantioxidant, a mold-release agent, an ultraviolet absorber, a dye orpigment, a flame retardant, an anti-dripping agent, a light-diffusingagent, an antistatic agent, an anti-fogging agent, a lubricant, ananti-blocking agent, a flow modifier, a sliding modifier, a plasticizer,a dispersant, and an antimicrobial agent. The resin additive agents maybe contained alone, or two or more of the resin additive agents may becontained at any ratio.

The descriptions of (Heat Stabilizer), (Antioxidant), (Mold-ReleaseAgent), (Ultraviolet Absorber), (Dye or Pigment), and (Anti-DrippingAgent) of <Resin Additive Agents> that may be contained in thepolycarbonate resin composition according to I. First Aspect of thePresent Invention can be applied to exemplary resin additive agents(Heat Stabilizer), (Antioxidant), (Mold-Release Agent), (UltravioletAbsorber), (Dye or Pigment), and (Anti-Dripping Agent) suitable for thepolycarbonate resin composition according to the sixth aspect of thepresent invention, respectively.

The description of (Light-Diffusing Agent) of <Resin Additive Agents>that may be contained in the polycarbonate resin composition accordingto II. Second Aspect of the Present Invention can be applied to(Light-Diffusing Agent).

6. Method for Producing Polycarbonate Resin Composition

A method for producing the polycarbonate resin composition according tothe sixth aspect of the present invention is not particularly limited.Various known methods for producing polycarbonate resin compositions canbe employed.

A specific example is a method in which the polycarbonate resinaccording to the sixth aspect of the present invention, a metal saltcompound, a polysilane having an aryl group, and other components to beoptionally blended are mixed in advance, for example, in a mixer, suchas a tumbler or a Henschel mixer, and are melt-kneaded in a mixer, suchas a Banbury mixer, a roll, a Brabender, a single-screw extruder, atwin-screw extruder, or a kneader.

Alternatively, for example, the components are not mixed in advance, orpart of the components is mixed in advance, and the components aresupplied to an extruder with a feeder and are melt-kneaded to produce apolycarbonate resin composition according to the present invention.

Alternatively, for example, part of the components is mixed in advanceand is supplied to and melt-kneaded in an extruder to produce a resincomposition as a masterbatch. This masterbatch is again mixed with theother components and is melt-kneaded to produce a polycarbonate resincomposition according to the present invention.

When a component that is difficult to disperse is mixed, the componentthat is difficult to disperse can be dissolved or dispersed in advancein a solvent, such as water or an organic solvent. The solution ordispersion liquid is kneaded with other components and thus highdispersibility can be achieved.

7. Polycarbonate Resin Formed Product

The polycarbonate resin composition according to the sixth aspect of thepresent invention is generally formed into polycarbonate resin formedproducts having any shape. The shape, design, color, and size of theformed products are not particularly limited and may be appropriatelydetermined in accordance with each application of the formed products.

Examples of the formed products include components of electrical andelectronic devices, OA equipment, information terminals, mechanicalparts, household electrical appliances, vehicle parts, architecturalmembers, various containers, recreational equipment and miscellaneousarticles, and illuminators. Among these, the formed products aresuitably used for components of electrical and electronic devices, OAequipment, information terminals, household electrical appliances, andilluminators and are particularly suitably used for components ofelectrical and electronic devices.

Examples of the electrical and electronic devices include personalcomputers, game machines, display units, such as television sets,printers, copying machines, scanners, facsimiles, electronic notebooksand PDAs, electronic calculators, electronic dictionaries, cameras,video cameras, cellular phones, battery packs, recording medium drivesand readers, mouses, numeric keypads, CD players, MD players, andportable radios and audio-players.

A method for manufacturing formed products is not particularly limited.Any common molding method for polycarbonate resin compositions can beemployed. Examples of the common molding method include an injectionmolding method, an ultra-high-speed injection molding method, aninjection compression molding method, a coinjection molding method,gas-assisted blow molding methods and the like, molding methods usinginsulated metal dies, molding methods using rapid heating metal dies,foam molding (including supercritical fluid), insert molding, an IMC(in-mold coating molding) molding method, an extrusion molding method, asheet forming method, a thermoforming method, a rotational moldingmethod, a laminate molding method, and a press forming method. Ahot-runner molding method may also be used.

As described above, the polycarbonate resin formed product according tothe sixth aspect of the present invention can be used as a practicalformed product having high flame resistance, transparency, and impactresistance and excellent hue without impairing excellent characteristicsof polycarbonate resins.

EXAMPLES

The invention according to the first aspect will now be specificallydescribed on the basis of Examples. The invention according to the firstaspect is not limited to Examples below, and any modification can bemade without departing from the gist of the present invention.

I. Examples and Comparative Examples according to First Aspect of thePresent Invention Production of Resin Pellet

The components shown in Table 1 below were blended with each other atthe ratios (mass ratios) shown in Table 2 and mixed in a tumbler for 20minutes. The mixture was supplied to (TEX30HSST) having a single ventand manufactured by The Japan Steel Works, Ltd. and kneaded at a numberof screw revolutions of 200 rpm, a discharge rate of 15 kg/hour, and abarrel temperature of 290° C. After that, a molten resin extruded in astrand shape was rapidly cooled in a water bath and pelletized using apelletizer to obtain a pellet of a polycarbonate resin composition.

[Preparation of Test Piece]

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm×50mm×2 mm in thickness) and an ASTM test piece (notched test piece with athickness of 3.2 mm).

[Evaluation of Water Repellency and Oil Repellency]

The water repellency of each polycarbonate resin composition wasevaluated as follows using, as a test piece, the flat test pieceobtained by the above-described method. A droplet of pure water wasdropped onto the test piece and the contact angle (unit: deg) wasmeasured by a θ/2 method using a DropMaster 300 contact angle analyzermanufactured by Kyowa Interface Science Co., Ltd. in an environment ofJIS standard temperature and humidity (23° C. and 50% RH). Tenmeasurement results were averaged to evaluate water repellency. The oilrepellency was evaluated by measuring a contact angle by the same methodas described above, except that a mixed solution of pure water:isopropylalcohol=1:1 was used as a droplet to be dropped. A higher value ofcontact angle means higher water repellency or oil repellency, which ispreferable. Table 2 shows the results.

[Evaluation of Impact Resistance]

The Izod impact strength (unit: J/m) was measured using the ASTM testpiece (notched test piece with a thickness of 3.2 mm) prepared above at23° C. in accordance with ASTM D256.

Table 2 shows the results. In Table 2, the impact resistance is given as“Izod”.

[Evaluation of Transparency]

The haze value (unit “%”) and the total light transmittance (unit “%”)were measured with an NDH-2000 haze meter manufactured by NIPPONDENSHOKU INDUSTRIES Co., Ltd. in accordance with JIS K-7105 using theflat test piece (2 mm in thickness) as a test piece.

The haze value is used as the scale of turbidity of resins. A smallerhaze value means higher transparency, which is preferable. The totallight transmittance is used as the scale of transmittancy of resins. Thetotal light transmittance is preferably high.

Table 2 shows the results. In Table 2, the haze value is given as “Hz”and the total light transmittance is given as “T”.

TABLE 1 Abbreviation Sample Polycarbonate (A) Aromatic polycarbonateresin produced by interfacial resin polymerization using bisphenol A asa starting material Product name: “Iupilon (registered trademark)S-3000N” manufactured by Mitsubishi Engineering-Plastics CorporationViscosity-average molecular weight: 21000 Polycarbosilane (B1)Polycarbosilane compound having a structure represented by compoundformula (6) Product name: “Nipusi Type-L” manufactured by Nippon CarbonCo., Ltd. Number-average molecular weight: 950, Melting point: 66° C.(B2) Polycarbosilane compound having a structure represented by formula(6) Product name: “Nipusi Type-A” manufactured by Nippon Carbon Co.,Ltd. Number-average molecular weight: 1500, Melting point: 248° C. (B3)Polycarbosilane compound having a structure represented by formula (6)Product name: “Nipusi Type-S” manufactured by Nippon Carbon Co., Ltd.Number-average molecular weight: 1600, Melting point: 234° C. Othersilicon (C1) Organosiloxane compound compounds PolydimethylsiloxaneProduct name: “SH200CV-100CS” manufactured by Dow Corning Toray Co.,Ltd. (D2) Polysilane compound Polydimethylsilane Number-averagemolecular weight: 2000

TABLE 2 Comparative Example Example Abbreviation Unit I-1 I-2 I-3 I-4I-5 I-6 I-7 I-1 I-2 I-3 Blending (A) parts 99.75 99.5 99 99 97 95 93 10099 99 ratio of (B1) by mass 0.25 0.5 1 polycarbonate (B2) 1 3 5 resin(B3) 7 (C1) 1 (C2) 1 Water repellency deg 80 81 85 80 84 87 90 77 82 82Oil repellency deg 20 25 27 21 17 13 12 11 26 12 Izod KJ/m² 69 69 65 6858 51 42 70 28 29 Hz % 1.1 1.3 6.9 2.3 5.8 8.8 11.8 1 99.3 99.3 T % 8988 85 89 88 87 85 89 40 42

It is clear from the results above that, by blending a polycarbosilanecompound, surface properties, such as water and oil repellency, can bemodified without significantly impairing the intrinsic characteristicsof the polycarbonate resin, such as transparency and impact resistance.

II. Examples and Comparative Examples according to Second Aspect of thePresent Invention Examples II-1 to 11 and Comparative Examples II-1 to11 Production of Resin Pellet

The components shown in Tables 4a and 4b below were blended with eachother at the ratios (mass ratios) shown in Tables 5a to 5d and mixed ina tumbler for 20 minutes. The mixture was supplied to (TEX30HSST) havinga single vent and manufactured by The Japan Steel Works, Ltd. andkneaded at a number of screw revolutions of 200 rpm, a discharge rate of15 kg/hour, and a barrel temperature of 290° C. After that, a moltenresin extruded in a strand shape was rapidly cooled in a water bath andpelletized using a pelletizer to obtain a pellet of a polycarbonateresin composition.

[Preparation of Test Piece]

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 260° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain test pieces for ULTest having a length of 125 mm, a width of 13 mm, and thicknesses of 3.2mm (⅛ inches) and 1.6 mm ( 1/16 inches).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain an ASTM test piece (notchedtest piece with a thickness of 3.2 mm) and a flat test piece (90 mm inwidth, 50 mm in length, and 3 mm in thickness).

<Evaluation of Flame Resistance>

The flame resistance of each polycarbonate resin composition wasevaluated as follows. The test pieces for UL Test prepared by the methodabove were left in a thermostatic chamber having a temperature of 23° C.and a humidity of 50% for 48 hours, and the flame resistance wasevaluated in accordance with the UL 94 Test (Test for flammability ofplastic materials for parts in devices and appliances) specified by theU.S.A. Underwriters Laboratories (UL). UL 94V is a method for evaluatingflame resistance from the lingering flame time and dripping propertiesafter a burner flame has been applied, for ten seconds, to a test piecehaving a predetermined size and held in the vertical position. Toachieve flame resistance of V-0, V-1, and V-2, the criteria shown inTable 3 below need to be satisfied.

TABLE 3 V-0 V-1 V-2 Lingering 10 sec or shorter  30 sec or shorter  30sec or shorter flame time for each specimen Total lingering 50 sec orshorter 250 sec or shorter 250 sec or shorter flame time for fivespecimens Cotton ignition No No Yes by drips

The lingering flame time is the duration of flaming combustion of a testpiece after an ignition source has been moved away. The cotton ignitionby drips is determined by whether or not marking cotton placed about 300mm below the bottom of the test piece is ignited by drips from the testpiece. Furthermore, the case where even one of five specimens does notsatisfy the criteria above was evaluated as NR (not rated) because thecase does not satisfy V-2.

Tables 5a to 5d show the results.

<Evaluation of Impact Resistance>

The Izod impact strength (unit: J/m) was measured using the ASTM testpiece (notched test piece with a thickness of 3.2 mm) prepared above at23° C. in accordance with ASTM D256.

Tables 5a to 5d show the results. In Tables 5a to 5d, the impactresistance is given as “Izod”.

<Evaluation of Outgassing>

When the flat test piece was injection-molded, the generation of gasfrom the nozzle tip of the injection molding machine was observedthrough visual inspection. The case where almost no gas was generatedwas evaluated as “Good” and the case where gas was significantlygenerated was evaluated as “Poor”.

Tables 5a to 5d show the results. In Tables 5a to 5d, outgassing isgiven as “low gassing property”

<Evaluation of Mold Fouling>

With a MINIMAT M8/7A molding machine manufactured by Sumitomo HeavyIndustries, Ltd., 500 shots of continuous molding were performed on thepellet obtained by the above-described production method, using a dropmold at a molding temperature of 290° C. and a mold temperature of 60°C. After that, the presence or absence of fouling in the mold wasobserved through visual inspection, and the mold fouling was evaluatedin accordance with the criteria below.

Tables 5a to 5d show the results.

Excellent: fouling in the mold is hardly observed.

Good: fouling in the mold is slightly observed.

Poor: a large amount of fouling in the mold is observed.

<Evaluation of Transparency>

The haze value (unit “%”) and the total light transmittance (unit “%”)were measured with an NDH-2000 haze meter manufactured by NIPPONDENSHOKU INDUSTRIES Co., Ltd. in accordance with JIS K-7105 using theflat test piece (3 mm in thickness) as a test piece.

The haze value is used as the scale of turbidity of resins. A smallerhaze value means higher transparency, which is preferable. The totallight transmittance is used as the scale of transmittancy of resins. Thetotal light transmittance is preferably high.

Tables 5a to 5d show the results.

In Tables 5a to 5d, the haze value is given as “3 mm Haze” and the totallight transmittance is given as “3 mm Transmittance”.

TABLE 4a Abbreviation Sample Polycarbonate resin (A1) Aromaticpolycarbonate resin produced by interfacial polymerization usingbisphenol A as a starting material Viscosity-average molecular weight:21000, Structural viscosity index: 1.0 (A2) Aromatic polycarbonate resinproduced by interfacial polymerization using bisphenol A as a startingmaterial Viscosity-average molecular weight: 17000, Structural viscosityindex: 1.0 (A3) Aromatic polycarbonate resin produced by melttransesterification using bisphenol A as a starting materialViscosity-average molecular weight: 27000, Structural viscosity index:1.3 (A4) Aromatic polycarbonate resin produced by interfacialpolymerization using bisphenol A as a starting materialViscosity-average molecular weight: 26000, Structural viscosity index:1.0 Metal salt compound (B1) Potassium perfluorobutanesulfonate Productname: “Bayowet C4” manufactured by LANXESS (B2) Cesiumparatoluenesulfonate Product name: “MEC-142” manufactured by TAKEMOTOOIL & FAT Co., Ltd. Polycarbosilane (C1) Polycarbosilane compound havinga structure compound represented by formula (6) Product name: “NipusiType-L” manufactured by Nippon Carbon Co., Ltd. Number-average molecularweight: 950, Melting point: 66° C. (C2) Polycarbosilane compound havinga structure represented by formula (6) Product name: “Nipusi Type-A”manufactured by Nippon Carbon Co., Ltd. Number-average molecular weight:1500, Melting point: 248° C. (C3) Polycarbosilane compound having astructure represented by formula (6) Product name: “Nipusi Type-S”manufactured by Nippon Carbon Co., Ltd. Number-average molecular weight:1600, Melting point: 234° C.

TABLE 4b Abbreviation Sample Other silicon (D1) Organosiloxane compoundcompounds Polymethylphenylsiloxane Product name: “PH 1555” manufacturedby Dow Corning Toray Co., Ltd. (D2) Organosiloxane compoundPolyphenylsiloxane (including a branched structure) Product name:“SR-21” manufactured by Konishi Chemical Inc. Co., Ltd. (D3)Organosiloxane compound Phenyltrimethoxysilane Product name: “AY 43-040”manufactured by Dow Corning Toray Co., Ltd. (D4) Organosiloxane compoundOctaphenyltetracyclosiloxane manufactured by Shin-Etsu Chemical Co.,Ltd. (D5) Polysilane compound Polydimethylsilane Number-averagemolecular weight: 2000 Stabilizer (E1) Heat stabilizerTris(2,4-di-tert-butylphenyl)phosphite Product name: “ADK STAB 2112”manufactured by Adeka Corp. (E2) Phenol antioxidant Pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate] Product name:“Irganox 1010” manufactured by Ciba Specialty Chemicals Co., Ltd.Anti-dripping (F) Aqueous dispersion liquid of fluoroolefin resin (thecontent agent of PTFE: 60% by weight) Product name: “31-JR” manufacturedby DU PONT-MITSUI FLUOROCHEMICALS COMPANY, Ltd. Light-diffusing (G)Polymethylsilsesquioxane particles having an average agent particle sizeof 2 μm (spherical) Product name: “Tospearl 120” manufactured byMomentive Performance Materials Inc. Mold-release (H1) Pentaerythritoltetrastearate agent Product name: “VPG 861” manufactured by Cognis JapanLtd. (H2) Stearyl stearate Product name: “Unistar M9676” manufactured byNOF Corporation

TABLE 5a Example Example Example Example Example Example ExampleAbbreviation Unit II-1 II-2 II-3 II-4 II-5 II-6 II-7 Resin (A1) parts99.72 99.395 99.645 99.395 99.645 99.395 99.87 composition (B1) by mass0.1 0.075 0.075 0.075 0.075 0.075 (B2) 0.1 (C1) 0.15 0.5 (C2) 0.25 0.5(C3) 0.25 0.5 1 (E1) 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Flame resistanceV-0 V-0 V-0 V-0 V-0 V-0 V-0 (3 mm) Izod J/m 700 690 680 670 710 700 690Low gassing Good Good Good Good Good Good Good property Mold foulingExcellent Good Excellent Excellent Excellent Excellent Excellent 3mmHaze % 1.9 3.8 2.1 3 1.6 2 3.1 3 mm % 89 87 90 90 90 90 90Transmittance

TABLE 5b Comparative Comparative Comparative Comparative ComparativeExample Example Example Example Example Abbreviation Unit II-1 II-2 II-3II-4 II-5 Resin (A1) parts 99.97 99.895 98.47 98.97 99.894 composition(B1) by mass 0.075 0.075 (C3) 0.5 1 0.001 (E1) 0.03 0.03 0.03 0.03 0.03Flame resistance V-2 V-2 V-2 V-2 V-2 (3 mm) Izod J/m 760 710 690 690 690Low gassing Good Good Good Good Good property Mold fouling ExcellentGood Excellent Excellent Excellent 3 mmHaze % 1.1 1 1.8 3 1.1 3 mm % 9090 90 90 90 Transmittance

TABLE 5c Example Example Example Example Abbreviation Unit II-8 II-9II-10 II-11 Resin composition (A2) parts by mass 29.65 29.4 29.15 29.65(A3) 70 70 70 70 (B1) 0.1 0.1 0.1 0.1 (C2) 0.25 0.5 0.75 (C3) 0.25 Flameresistance V-0 V-0 V-0 V-0 (3 mm) Izod J/m 660 580 680 660 Low gassingGood Good Good Good property Mold fouling Excellent Excellent ExcellentExcellent 3 mmHaze % 4.3 6.3 7.1 3.2 3 mm % 88 88 88 88 Transmittance

TABLE 5d Comparative Comparative Comparative Comparative ComparativeComparative Example Example Example Example Example Example AbbreviationUnit II-6 II-7 II-8 II-9 II-10 II-11 Resin (A1) parts 19.37 28.9 18.8718.87 composition (A2) by mass 29.9 29.42 (A3) 70 80 70 80 80 70 (B1)0.1 0.1 0.1 0.1 0.1 0.08 (D1) 0.5 (D2) 1 (D3) 1 (D4) 1 (D5) 0.5 (E1)0.03 0.03 0.03 Flame resistance V-2 V-0 V-1 V-2 V-2 V-0 (3 mm) Izod J/m660 610 450 580 640 340 Low gassing Good Poor Good Poor Poor Goodproperty Mold fouling Excellent Poor Good Poor Poor Excellent 3 mmHaze %0.7 0.4 26 0.5 0.4 99 3 mm % 88 88 86 88 88 44 Transmittance

It is clear from the results above that the polycarbonate resincomposition of the present invention obtained by blending a metal saltcompound and a polycarbosilane compound with a polycarbonate resin hashigh flame resistance, impact resistance, and transparency and causesless outgassing and mold fouling.

Example II-12 and Comparative Example II-12 Production of Resin Pellet

The components shown in Tables 4a and 4b above were blended with eachother at the ratios (mass ratios) shown in Table 6 and mixed in atumbler for 20 minutes. The mixture was supplied to (TEX30HSST) having asingle vent and manufactured by The Japan Steel Works, Ltd. and kneadedat a number of screw revolutions of 200 rpm, a discharge rate of 15kg/hour, and a barrel temperature of 290° C. After that, a molten resinextruded in a strand shape was rapidly cooled in a water bath andpelletized using a pelletizer to obtain a pellet of a polycarbonateresin composition.

<Evaluation of Flowability (Q value)>

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then the flow rate per unit time, Qvalue (unit: 10⁻² cm³/sec), of a composition was measured by a methoddescribed in Appendix C of JIS K7210 using a Koka-shiki Flow Tester at280° C. at a load of 160 kgf to evaluate the flowability. Note that anorifice having 1 mm in diameter and 10 mm in length was used. A higher Qvalue means higher flowability. Table 6 shows the results.

<Preparation of Test Piece>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain test pieces for ULTest having a length of 125 mm, a width of 13 mm, and thicknesses of 1.2mm and 1.0 mm.

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, three steps of 1, 2, and 3 mm in thickness).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours and then injection-molded at a cylindertemperature of 290° C., a mold temperature of 80° C., and a moldingcycle of 45 seconds using a Cycap M-2 with a clamping force of 75 Tmanufactured by Sumitomo Heavy Industries, Ltd. to obtain an ISOmultipurpose test piece (4 mm) and an ISO multipurpose test piece (3mm).

<Evaluation of Flame Resistance>

The flame resistance was evaluated by performing UL Test in the samemanner as in Example II-1 using the test pieces for UL Test.

Table 6 shows the results.

<Evaluation of Turbidity>

In a three-millimeter-thickness portion of the flat test piece (withthree steps of 1, 2, and 3 mm in thickness), the turbidity was measuredin accordance with JIS K-7136 using an NDH-2000 turbidimetermanufactured by NIPPON DENSHOKU INDUSTRIES Co., Ltd. The turbidity isused as the scale of cloudiness of resins. A lower turbidity value meanshigher transparency. Table 6 shows the results.

<Evaluation of Diffusivity/Degree of Dispersion>

In a one-millimeter-thickness portion and a two-millimeter-thicknessportion of the flat test piece (with three steps of 1, 2, and 3 mm inthickness), the brightness was measured with GP-5 GONIOPHOTOMETERmanufactured by MURAKAMI COLOR RESEARCH LABORATORY under the conditionsthat incident light was at 0°, the elevation angle was 0°, thelight-receiving range was 0° to 90°, the luminous aperture was 2.0, andthe light-receiving aperture was 3.0. The diffusivity (%) was determinedfrom the following formula. The degree of dispersion indicates alight-receiving angle that provides 50% of brightness at alight-receiving angle of 0°, that is, 50% of brightness of a light beamwhich travels in a straight line after passing through the test piecefrom a light source. Table 6 shows the results.

Diffusivity (%)=100·[(brightness at a light-receiving angle of20°+brightness at a light-receiving angle of 70°)/{2·(brightness at alight-receiving angle of 5°)}]

<Evaluation of Heat Resistance>

The deflection temperature under load was measured in accordance withISO 75-1 and ISO 75-2 using the ISO multipurpose test piece (4 mm) at aload of 1.80 MPa. Table 6 shows the results. In Table 6, the deflectiontemperature under load is given as “DTUL”.

<Evaluation of Bendability>

The bending stress and bending modulus were measured in accordance withISO 178 using the ISO multipurpose test piece (4 mm) at 23° C. Table 6shows the results.

<Evaluation of Impact Resistance>

The notched Charpy impact strength (unit: kJ/m²) was measured inaccordance with ISO 179 using the ISO multipurpose test piece (3 mm) at23° C. Table 6 shows the results.

TABLE 6 Comparative Example Example Abbreviation Unit II-12 II-12 Resin(A4) parts by 17.98 18.98 composition (A3) mass 80 80 (B1) 0.09 0.09 (F)0.17 0.17 (C2) 1 (G) 0.5 0.5 (H1) 0.1 0.1 (H2) 0.1 0.1 (E1) 0.03 0.03(E2) 0.03 0.03 Flowability (Q value) 10⁻² cm³/ 8.4 4.5 sec Flame 1.2 mmV-0 V-0 resistance in thickness 1.0 mm V-2 V-1 in thickness Turbidity Hz(1 mm) % 99.0 99.1 Hz (2 mm) % 99.3 99.3 Diffusivity/ Diffusivity (1 mm)45.5 45.6 Degree of Degree of 34.8 34.7 dispersion dispersion (1 mm)Diffusivity (2 mm) 56.6 57.2 Degree of 49.4 50.3 dispersion (2 mm) DTUL° C. 125 126 Bendability Elastic modulus MPa 2310 2380 (load) Bendingstress MPa 97 99 Impact resistance kJ/m² 60 65

It is clear from Table 6 that a satisfactory light-diffusing effect isachieved by blending a light-diffusing agent.

III. Examples and Comparative Examples of Third aspect of the PresentInvention Examples III-1 to 18 and Comparative Examples III-1 to 3Production of Resin Pellet

The components shown in Tables 8a and 8b below were blended with eachother at the ratios (mass ratios) shown in Tables 9 and 10 and mixed ina tumbler for 20 minutes. The mixture was supplied to (TEX30HSST) havinga single vent and manufactured by The Japan Steel Works, Ltd. andkneaded at a number of screw revolutions of 200 rpm, a discharge rate of15 kg/hour, and a barrel temperature of 290° C. After that, a moltenresin extruded in a strand shape was rapidly cooled in a water bath andpelletized using a pelletizer to obtain a pellet of a polycarbonateresin composition.

[Preparation of Test Piece]

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, and 1 mm in thickness).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours and then injection-molded at a cylindertemperature of 290° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain a test piece forUL Test having a length of 125 mm, a width of 13 mm, and a thickness of1.2 mm.

<Evaluation of Near-infrared Light Transmittance>

The light transmittance in a near-infrared region ranging from 800 nm to1500 nm (near-infrared light transmittance) was measured with a spectrallight transmittance analyzer “UV-3100” manufactured by SHIMADZUCorporation using the flat test piece (1 mm in thickness) as a testpiece. Tables 9 and 10 show the results.

<Evaluation of Flame Resistance>

The test piece for UL Test prepared above was left in a thermostaticchamber having a temperature of 23° C. and a humidity of 50% for 48hours, and the flame resistance was evaluated in accordance with the UL94 Test (Test for flammability of plastic materials for parts in devicesand appliances) specified by the U.S.A. Underwriters Laboratories (UL).

UL 94V is a method for evaluating flame resistance from the lingeringflame time and dripping properties after a burner flame has beenapplied, for ten seconds, to a test piece having a predetermined sizeand held in the vertical position. To achieve flame resistance of V-0,V-1, and V-2, the criteria shown in Table 7 below need to be satisfied.

TABLE 7 V-0 V-1 V-2 Lingering flame time for 10 sec or 30 sec or 30 secor each specimen shorter shorter shorter Total lingering flame 50 sec or250 sec or 250 sec or time for five specimens shorter shorter shorterCotton ignition by drips No No Yes

The lingering flame time is the duration of flaming combustion of a testpiece after an ignition source has been moved away. The cotton ignitionby drips is determined by whether or not marking cotton placed about 300mm below the bottom of the test piece is ignited by drips from the testpiece. Furthermore, the case where even one of five specimens does notsatisfy the criteria above was evaluated as NR (not rated) because thecase does not satisfy V-2.

Tables 9 and 10 show the results.

TABLE 8a Abbreviation Sample Thermoplastic resin (A1) Aromaticpolycarbonate resin produced by interfacial polymerization usingbisphenol A as a starting material Product name: “Iupilon (registeredtrademark) S-3000N” manufactured by Mitsubishi Engineering-PlasticsCorporation Viscosity-average molecular weight: 21000 Thermoplasticresin (A2) Aromatic polycarbonate resin produced by interfacialpolymerization using bisphenol A as a starting material Product name:“Iupilon (registered trademark) H-4000N” manufactured by MitsubishiEngineering-Plastics Corporation Viscosity-average molecular weight:15000 Fluoropolymer (B) Polytetrafluoroethylene capable of formingfibrils Product name: “Teflon (registered trademark) 6J” manufactured byDuPont-Mitsui Fluorochemicals Co., Ltd. Fluoropolymer (C1)Polycarbosilane compound having a structure represented by dispersantformula (6) Product name: “Nipusi Type-A” manufactured by Nippon CarbonCo., Ltd. Number-average molecular weight: 1500, Melting point: 248° C.(C2) Polycarbosilane compound having a structure represented by formula(6) Product name: “Nipusi Type-S” manufactured by Nippon Carbon Co.,Ltd. Number-average molecular weight: 1600, Melting point: 234° C. (C3)Polycarbosilane compound having a structure represented by formula (6)Product name: “Nipusi Type-L” manufactured by Nippon Carbon Co., Ltd.Number-average molecular weight: 950, Melting point: 66° C.

TABLE 8b Abbreviation Sample Flame retardant (D1) Metal salt compound,potassium perfluorobutanesulfonate Product name: “Bayowet C4”manufactured by LANXESS (D2) Metal salt compound, sodiumparatoluenesulfonate Product name: “Chemguard-NATS” manufactured byChembridge International Corp. Other resins (E)Poly-4,4′-isopropylidene-diphenyl carbonate oligomer Product name:“AL071” manufactured by Mitsubishi Engineering-Plastics CorporationFibrous reinforcement (F1) Glass fiber-chopped strand Product name:“ECS03T571” manufactured by Nippon Electric Glass Co., Ltd. Averagefiber diameter: 13 μm, Average length: 3 mm (F2) Milled glass fiberProduct name: “EPG70M99S” manufactured by Nippon Electric Glass Co.,Ltd. Average fiber diameter: 9 μm, Average length: 70 μm Mold-releaseagent (G1) Polyethylene wax Product name: “Licowax PE-520PW”manufactured by Clariant (Japan) K.K., Dropping point: 117 to 122° C.(G2) Stearic acid Product name: “NAA180” manufactured by NOF Corporation(G3) Pentaerythritol distearate Product name: “Unistar H476D”manufactured by NOF Corporation Optical function (H) Titanium oxideregulator Product name: “CRNOSS2233” manufactured by KRONOS Averageparticle size: 0.20 μm

TABLE 9 Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam-Exam- Exam- Abbre- ple ple ple ple ple ple ple ple ple ple ple pleviation Unit III-1 III-2 III-3 III-4 III-5 III-6 III-7 III-8 III-9III-10 III-11 III-12 Resin (A1) parts 98.5 99.45 99.4 99.3 99.25 99.2599.25 99.2 99 99 98.5 98.5 composition (B) by 0.4 0.4 0.4 0.4 0.4 0.40.4 0.4 0.4 0.4 0.4 0.4 (C1) mass 1 0.25 0.5 1 (C2) 0.05 0.1 0.2 0.250.3 0.5 1 (C3) 0.25 (D1) 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1(D2) Near- 1000 nm % 58.49 49.03 47.45 49.08 56.35 54.74 49.66 49.0856.44 55.65 59.79 54.74 infrared 1050 nm 60.95 52.70 51.78 52.89 59.6657.95 53.02 52.89 59.43 58.83 62.39 57.49 light 1100 nm 62.70 55.5454.43 55.40 61.72 59.88 55.95 55.40 61.55 60.74 64.47 59.52 transmit-1150 nm 63.63 57.24 56.15 57.32 62.99 61.04 57.75 57.32 62.78 61.7465.35 60.59 tance 1200 nm 66.42 60.89 60.07 60.94 66.34 64.38 62.0460.94 66.00 64.88 68.23 63.52 1250 nm 68.57 63.92 63.07 63.82 68.7566.82 65.32 63.82 68.43 67.30 70.68 65.93 1300 nm 69.42 65.48 64.7665.42 69.92 67.93 66.42 65.42 69.54 68.27 71.63 66.88 1350 nm 68.7666.06 64.84 65.52 69.61 67.76 66.52 65.52 69.42 68.26 71.38 67.12 1400nm 67.02 64.94 64.01 64.81 68.23 66.04 65.46 64.81 67.59 66.40 69.5565.04 1450 nm 69.32 67.58 66.78 67.41 70.82 68.51 67.89 67.41 70.1368.75 71.84 67.29 1500 nm 71.63 70.16 69.56 70.13 73.24 71.05 71.0170.13 72.47 71.05 74.17 69.48 Flame resistance V-1 V-1 V-0 V-0 V-0 V-0V-1 V-1 V-1 V-0 V-0 V-0 Total combustion sec 60 53 43 39 28 20 70 37 6524 34 30 time

TABLE 10 Comparative Comparative Comparative Abbre- Example ExampleExample Example Example Example Example Example Example viation UnitIII-13 III-14 III-15 III-16 III-17 III-18 III-1 III-2 III-3 Resin (A1)parts 98 97.5 96.5 94.5 99.25 99 99.6 99.5 99.5 composition (B) by mass0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 (C1) (C2) 1.5 2 3 5 0.25 0.5 (C3)(D1) 0.1 0.1 0.1 0.1 0.1 (D2) 0.1 0.1 0.1 Near- 1000 nm % 52.00 54.8258.46 62.03 54.54 55.48 44.72 39.01 38.86 infrared 1050 nm 55.92 58.3661.44 65.42 57.77 58.66 47.79 42.99 42.78 light 1100 nm 58.27 60.5463.62 67.48 59.62 60.54 50.15 46.20 46.01 transmittance 1150 nm 59.5761.63 64.64 67.80 60.86 61.51 51.96 48.66 48.48 1200 nm 62.96 65.0567.71 70.67 64.14 64.63 55.26 52.59 52.42 1250 nm 65.59 67.88 70.2773.31 66.59 67.14 57.81 55.73 55.51 1300 nm 66.93 69.06 71.38 74.2167.78 68.02 59.41 57.62 57.45 1350 nm 66.80 69.25 71.04 74.04 67.5667.98 59.21 58.26 58.02 1400 nm 65.68 67.62 69.62 72.02 65.81 66.1758.09 57.88 57.68 1450 nm 68.14 70.18 72.05 74.37 68.34 68.52 60.5460.63 60.41 1500 nm 70.78 72.51 74.54 76.46 70.84 70.81 63.17 63.6463.46 Flame resistance V-0 V-1 V-1 V-1 V-0 V-0 V-2 V-2 V-2 Totalcombustion sec 46 51 66 66 28 42 67 57 101 time

It is clear from the results above that the near-infrared lighttransmittance and flame resistance can be improved by blending apolycarbosilane compound as a fluoropolymer dispersant.

Examples III-19 and 20 and Comparative Examples III-4 and 5 Productionof Resin Pellet

The components shown in Tables 8a and 8b above were blended with eachother at the ratios (mass ratios) shown in Tables 11 and 12 and mixed ina tumbler for 20 minutes. The mixture was supplied to (TEX30HSST) havinga single vent and manufactured by The Japan Steel Works, Ltd. andkneaded at a number of screw revolutions of 200 rpm, a discharge rate of15 kg/hour, and a barrel temperature of 290° C. After that, a moltenresin extruded in a strand shape was rapidly cooled in a water bath andpelletized using a pelletizer to obtain a pellet of a polycarbonateresin composition.

<Evaluation of Flowability> MVR (Melt Volume Rate)

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then measurement was performed inaccordance with ISO 1133 at a measurement temperature of 300° C. and ameasurement load of 1.2 kgf (11.8 N). Table 11 shows the results.

Q value

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then the flow rate per unit time, Qvalue (unit: 10⁻² cm³/sec), of a composition was measured by a methoddescribed in Appendix C of JIS K7210 using a Koka-shiki Flow Tester at280° C. at a load of 160 kgf to evaluate the flowability. Note that anorifice having 1 mm in diameter and 10 mm in length was used. A higher Qvalue means higher flowability. Table 12 shows the results.

<Preparation of Test Piece>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours. In the case where the fibrous reinforcement wasnot contained, the pellet was injection-molded at a cylinder temperatureof 280° C., a mold temperature of 80° C., and a molding cycle of 30seconds using a J50-EP injection molding machine manufactured by TheJapan Steel Works, Ltd. In the case where the fibrous reinforcement wascontained, the pellet was injection-molded at a cylinder temperature of300° C., a mold temperature of 110° C., and a molding cycle of 30seconds. As a result, test pieces for UL Test having a length of 125 mm,a width of 13 mm, and thicknesses of 1.58 mm and 1.2 mm were molded.

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, and three steps of 1, 2, and 3 mm in thickness).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours. In the case where the fibrousreinforcement was not contained, the pellet was injection-molded at acylinder temperature of 280° C., a mold temperature of 80° C., and amolding cycle of 45 seconds using a Cycap M-2 with a clamping force of75 T manufactured by Sumitomo Heavy Industries, Ltd. In the case wherethe fibrous reinforcement was contained, the pellet was injection-moldedat a cylinder temperature of 300° C., a mold temperature of 110° C., anda molding cycle of 45 seconds. As a result, an ISO multipurpose testpiece (4 mm) and an ISO multipurpose test piece (3 mm) were molded.

<Evaluation of Flame Resistance>

The flame resistance was evaluated by performing UL Test in the samemanner as in Example III-1 using the test pieces for UL Test.

Tables 11 and 12 show the results.

<Evaluation of Reflectivity>

The reflectivity was measured using a three-millimeter-thickness portionof the flat test piece (having three steps of 1, 2, and 3 mm inthickness). The measurement was performed using Spectrophotometer CM3600d manufactured by KONICA MINOLTA HOLDINGS, INC. at a D65/10-degreeobserver with an SCl normal measurement mode. The reflectivity wasevaluated at a wavelength of 440 nm. Table 12 shows the results.

<Evaluation of Heat Resistance>

The deflection temperature under load was measured in accordance withISO 75-1 and ISO 75-2 using the ISO multipurpose test piece (4 mm) at aload of 1.80 MPa. Tables 11 and 12 show the results. In Tables 11 and12, the deflection temperature under load is given as “DTUL”.

<Evaluation of Bendability>

The bending stress and bending modulus were measured in accordance withISO 178 using the ISO multipurpose test piece (4 mm) at 23° C. Tables 11and 12 show the results.

<Evaluation of Impact Resistance>

The notched Charpy impact strength (unit: kJ/m²) was measured inaccordance with ISO 179 using the ISO multipurpose test piece (3 mm) at23° C. Tables 11 and 12 show the results.

TABLE 11 Comparative Example Example Abbreviation Unit III-19 III-4Resin (A1) parts by 68.32 69.32 composition (E) mass 10 10 (D1) 0.080.08 (B) 0.1 0.1 (C2) 1 (F1) 15 15 (F2) 5 5 (G1) 0.5 0.5 Flowability MVRcm³/10 min 11 10 Flame resistance UL94 V-0 V-1 (1.58 mm in thickness)DTUL ° C. 139 139 Bendability Elastic modulus MPa 5430 5520 (load)Bending stress MPa 151 141 Impact resistance kJ/m² 7 8

TABLE 12 Comparative Example Example Abbreviation Unit III-20 III-5Resin (A1) parts by 43.24 44.24 composition (A2) mass 43 43 (D2) 0.2 0.2(B) 0.4 0.4 (C2) 1 (H) 12 12 (G2) 0.08 0.08 (G3) 0.08 0.08 Flowability Qvalue 10⁻² cm³/sec 15.8 14.7 Flame resistance UL94 V-0 V-0 (1.2 mm inthickness) Reflectivity % 94.6 94.8 DTUL ° C. 126 125 BendabilityElastic modulus MPa 2440 2420 (load) Bending stress MPa 93 90 Impactresistance kJ/m² 33 41

It is clear from Table 11 that the bendability is improved through theblend of a fibrous reinforcement.

It is clear from Table 12 that the reflectivity is improved through theblend of titanium oxide.

IV. Examples and Comparative Examples according to Fourth Aspect of thePresent Invention

The following components were used in these Examples and ComparativeExamples.

PC 1: Polycarbonate resin (bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, Iupilon (registered trademark)S-3000 manufactured by Mitsubishi Engineering-Plastics Corporation,viscosity-average molecular weight: 21000, structural viscosity index:1.0)

PC 2: Polycarbonate resin (bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, viscosity-average molecularweight: 17000, structural viscosity index: 1.0)

PC 3: Polycarbonate resin (bisphenol A-type aromatic polycarbonate resinproduced by melt transesterification, viscosity-average molecularweight: 27000, structural viscosity index: 1.3)

M1: Metal salt compound (potassium perfluorobutanesulfonate, Bayowet C4manufactured by LANXESS)

M2: Metal salt compound (sodium toluenesulfonate manufactured by TOKYOCHEMICAL INDUSTRY Co., Ltd.)

PS: Polysilane (polydimethylsilane, number-average molecular weight:2000)

Stab: Heat stabilizer (tris(2,4-di-tert-butylphenyl)phosphite, ADK STAB2112 manufactured by Adeka Corp.)

[Production of Resin Pellet]

The components described above were blended with each other at theratios (mass ratios) shown in Tables 14 to 16 and mixed in a tumbler for20 minutes. The mixture was supplied to (TEX30HSST) having a single ventand manufactured by The Japan Steel Works, Ltd. and kneaded at a numberof screw revolutions of 200 rpm, a discharge rate of 15 kg/hour, and abarrel temperature of 270° C. After that, a molten resin extruded in astrand shape was rapidly cooled in a water bath and pelletized using apelletizer to obtain a pellet of a polycarbonate resin composition.

[Preparation of Test Piece for UL Test]

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 260° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain test pieces havinga length of 125 mm, a width of 13 mm, and thicknesses of 3.2 mm (⅛inches) and 1.6 mm ( 1/16 inches). The resultant formed products wereused as samples for UL Test, and the flame resistance was evaluated bythe method described below.

[Evaluation of Flame Resistance]

The flame resistance of each polycarbonate resin composition wasevaluated as follows. The test pieces for UL Test prepared by the methodabove were left in a thermostatic chamber having a temperature of 23° C.and a humidity of 50% for 48 hours, and the flame resistance wasevaluated in accordance with the UL 94 Test (Test for flammability ofplastic materials for parts in devices and appliances) specified by theU.S.A. Underwriters Laboratories (UL). UL 94V is a method for evaluatingflame resistance from the lingering flame time and dripping propertiesafter a burner flame has been applied, for ten seconds, to a test piecehaving a predetermined size and held in the vertical position. Toachieve flame resistance of V-0, V-1, and V-2, the criteria shown inTable 13 below need to be satisfied.

TABLE 13 V-0 V-1 V-2 Lingering flame time for 10 sec or 30 sec or 30 secor each specimen shorter shorter shorter Total lingering flame 50 sec or250 sec or 250 sec or time for five specimens shorter shorter shorterCotton ignition by drips No Yes Yes

The lingering flame time is the duration of flaming combustion of a testpiece after an ignition source has been moved away. The cotton ignitionby drips is determined by whether or not marking cotton placed about 300mm below the bottom of the test piece is ignited by drips from the testpiece. Furthermore, the case where even one of five specimens does notsatisfy the criteria above was evaluated as NR (not rated) because thecase does not satisfy V-2.

[Evaluation of Flowability]

Regarding the resin composition dried at 120° C. for 5 hours, the meltvolume rate per unit time (unit: cm³/10 min) was measured and evaluatedin accordance with JIS K7210 using Melt Indexer manufactured by ToyoSeiki Seisaku-sho, Ltd. at 300° C. at a load of 11.8 N.

TABLE 14 Example Example Example Example Example IV-1 IV-2 IV-3 IV-4IV-5 Blending PC1 parts 99.62 99.395 98.895 97.87 98.87 ratio of M1 bymass 0.1 0.075 0.075 0.1 polycarbonate M2 0.1 resin PS 0.25 0.5 1 2 1composition Stab 0.03 0.03 0.03 0.03 0.03 Flame resistance (⅛ inches)V-0 V-0 V-0 V-0 V-1 MVR (cm³/10 min) 17 17 17 18 17

TABLE 15 Comparative Comparative Comparative Comparative Example ExampleExample Example IV-1 IV-2 IV-3 IV-4 Blending PC1 parts 99.895 99.8799.47 98.97 ratio of M1 by mass 0.075 polycarbonate M2 0.1 resin PS 0.51 composition Stab 0.03 0.03 0.03 0.03 Flame resistance (⅛ inches) V-2V-2 V-2 V-2 MVR (cm³/10 min) 15 15 17 17

TABLE 16 Comparative Comparative Example Example Example Example IV-6IV-7 IV-5 IV-6 Blending PC2 parts 29.875 29.825 29.925 29.9 ratio of PC3by mass 70 70 70 70 polycarbonate M1 0.075 0.075 0.075 resin PS 0.05 0.10.1 composition Flame resistance ( 1/16 inches) V-0 V-0 V-2 V-2 MVR(cm³/10 min) 8 7 6 6

As is clear from Tables 14 to 16, the polycarbonate resin compositionsof Examples IV-1 to 5 have high flame resistance and flowability whereasthe polycarbonate resin compositions of Comparative Examples IV-1 and 2that contain only a metal salt compound and those of ComparativeExamples IV-3 and 4 that contain only a polysilane have insufficientflame resistance. As is also clear from Table 16, even in the case wherean aromatic polycarbonate resin having a predetermined structuralviscosity index is contained, the polycarbonate resin composition ofComparative Example IV-5 that contains only a metal salt compound andthat of Comparative Example IV-6 that contains only a polysilane haveinsufficient flame resistance. In contrast, the polycarbonate resincompositions of Examples IV-6 and 7 that contain both a metal saltcompound and a polysilane have high flame resistance.

Accordingly, it was confirmed from Examples and Comparative Examplesdescribed above that the effects of improving flame resistance andflowability could be uniquely achieved through the configurationaccording to the fourth aspect of the present invention.

V. Examples and Comparative Examples according to Fifth Aspect of thePresent Invention

The following components were used in Examples and Comparative Examples.

Polycarbonate resin-1 (bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, Iupilon (registered trademark)S-3000 manufactured by Mitsubishi Engineering-Plastics Corporation,viscosity-average molecular weight: 21000). In Tables 18 and 19, this isabbreviated as “PC-1”.

Polycarbonate resin-2 (bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, Iupilon (registered trademark)H-4000 manufactured by Mitsubishi Engineering-Plastics Corporation,viscosity-average molecular weight: 15000). In Tables 18 to 21, this isabbreviated as “PC-2”.

Metal salt compound 1 (potassium perfluorobutanesulfonate, Bayowet C4manufactured by LANXESS). In Tables 18 to 21, this is abbreviated as“Metal salt-1”.

Metal salt compound 2 (sodium toluenesulfonate, NATS manufactured byChembridge International Corp.). In Tables 18 to 21, this is abbreviatedas “Metal salt-2”.

Fluoropolymer (fluoroethylene resin capable of forming fibrils, Teflon(registered trademark) 6J manufactured by DuPont-Mitsui FluorochemicalsCo., Ltd.). In Tables 18 to 21, this is abbreviated as “PTFE”.

Polysilane (polydimethylsilane manufactured by Nippon Soda Co., Ltd.,number-average molecular weight: 2000). In Tables 18 to 21, this isabbreviated as “PS”.

Polycarbonate oligomer (poly-4,4′-isopropylidene-diphenyl carbonateoligomer, AL-071 manufactured by Mitsubishi Engineering-PlasticsCorporation). In Tables 18 to 21, this is abbreviated as “PC oligomer”.

Fibrous reinforcement-1 (glass fiber-chopped strand, ECS03T571manufactured by Nippon Electric Glass Co., Ltd.) (average fiberdiameter: 13 average length: 3 mm). In Tables 18 to 21, this isabbreviated as “GF-1”.

Fibrous reinforcement-2 (milled glass fiber, EPG70M99S manufactured byNippon Electric Glass Co., Ltd.) (average fiber diameter: 9 μm, averagelength: 70 μm). In Tables 18 to 21, this is abbreviated as “GF-2”.

Optical function regulator (titanium oxide, CRONOSS2233 manufactured byKRONOS) (average particle size: 0.20 μm). In Tables 18 to 21, this isgiven as “titanium oxide”.

Mold-release agent-1 (polyethylene wax, Licowax PE-520PW manufactured byClariant (Japan) K.K., Dropping point: 117 to 122° C.). In Tables 18 to21, this is given as “Mold-release agent-1”.

Mold-release agent-2 (stearic acid, NAA180 manufactured by NOFCorporation). In Tables 18 to 21, this is given as “Mold-releaseagent-2”.

Mold-release agent-3 (pentaerythritol distearate, Unistar H476Dmanufactured by NOF Corporation). In Tables 18 to 21, this is given as“Mold-release agent-3”.

Examples V-1 to 4 and Comparative Examples V-1 to 4 Production of ResinPellet

The components described above were blended with each other at theratios (mass ratios) shown in Tables 18 and 19 and mixed in a tumblerfor 20 minutes. The mixture was supplied to (TEX30HSST) having a singlevent and manufactured by The Japan Steel Works, Ltd. and kneaded at anumber of screw revolutions of 200 rpm, a discharge rate of 15 kg/hour,and a barrel temperature of 270° C. After that, a molten resin extrudedin a strand shape was rapidly cooled in a water bath and pelletizedusing a pelletizer to obtain a pellet of a polycarbonate resincomposition.

<Preparation of Test Piece for UL Test>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 260° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain a test piecehaving a length of 125 mm, a width of 13 mm, and a thickness of 1.0 mm.The resultant formed product was used as a sample for UL Test, and theflame resistance was evaluated by the method described below.

<Evaluation of Flame Resistance>

The flame resistance of each polycarbonate resin composition wasevaluated as follows. The test piece for UL Test prepared by the methodabove was left in a thermostatic chamber having a temperature of 23° C.and a humidity of 50% for 48 hours, and the flame resistance wasevaluated in accordance with the UL 94 Test (Test for flammability ofplastic materials for parts in devices and appliances) specified by theU.S.A. Underwriters Laboratories (UL). UL 94V is a method for evaluatingflame resistance from the lingering flame time and dripping propertiesafter a burner flame has been applied, for ten seconds, to a test piecehaving a predetermined size and held in the vertical position. Toachieve flame resistance of V-0, V-1, and V-2, the criteria shown inTable 17 below need to be satisfied.

TABLE 17 V-0 V-1 V-2 Lingering 10 sec or shorter  30 sec or shorter  30sec or shorter flame time for each specimen Total lingering 50 sec orshorter 250 sec or shorter 250 sec or shorter flame time for fivespecimens Cotton ignition No No Yes by drips

The lingering flame time is the duration of flaming combustion of a testpiece after an ignition source has been moved away. The cotton ignitionby drips is determined by whether or not marking cotton placed about 300mm below the bottom of the test piece is ignited by drips from the testpiece. Furthermore, the case where even one of five specimens does notsatisfy the criteria above was evaluated as NR (not rated) because thecase does not satisfy V-2. Tables 18 and 19 show the results.

TABLE 18 Example Example Example Example V-1 V-2 V-3 V-4 Resin PC-1parts 99.45 99.425 99.4 99 compo- Metal by 0.1 0.1 0.1 0.1 sition salt-1mass PTFE 0.4 0.4 0.4 0.4 PS 0.05 0.075 0.1 0.5 Flame resistance V-1 V-1V-1 V-1 (1.0 mm in thickness) Total combustion time 88 85 66 57 (sec)Number of times of drips 0 0 0 0 (out of 10)

TABLE 19 Com- Com- Com- Com- partive partive partive partive ExampleExample Example Example V-1 V-2 V-3 V-4 Resin PC-1 parts 99.5 99.49596.5 99.8 compo- Metal by 0.1 0.1 0.1 0.1 sition salt-1 mass PTFE 0.40.4 0.4 PS 0.005 3 0.1 Flame resistance V-2 V-2 NR V-2 (1.0 mm inthickness) Number of times of drips 3 2 — 5 (out of 10)

Examples V-5 and 6 and Comparative Examples V-5 and 6 Production ofResin Pellet

The components described above were blended with each other at theratios (mass ratios) shown in Tables 20 and 21 and mixed in a tumblerfor 20 minutes. The mixture was supplied to (TEX30HSST) having a singlevent and manufactured by The Japan Steel Works, Ltd. and kneaded at anumber of screw revolutions of 200 rpm, a discharge rate of 15 kg/hour,and a barrel temperature of 270° C. After that, a molten resin extrudedin a strand shape was rapidly cooled in a water bath and pelletizedusing a pelletizer to obtain a pellet of a polycarbonate resincomposition.

<Evaluation of Flowability> MVR (Melt Volume Rate)

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then measurement was performed inaccordance with ISO 1133 at a measurement temperature of 300° C. and ameasurement load of 1.2 kgf (11.8 N). Table 20 shows the results.

Q Value

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then the flow rate per unit time, Qvalue (unit: 10⁻² cm³/sec), of a composition was measured by a methoddescribed in Appendix C of JIS K7210 using a Koka-shiki Flow Tester at280° C. at a load of 160 kgf to evaluate the flowability. Note that anorifice having 1 mm in diameter and 10 mm in length was used. A higher Qvalue means higher flowability. Table 21 shows the results.

<Preparation of Test Piece>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours. In the case where the fibrous reinforcement wasnot contained, the pellet was injection-molded at a cylinder temperatureof 280° C., a mold temperature of 80° C., and a molding cycle of 30seconds using a J50-EP injection molding machine manufactured by TheJapan Steel Works, Ltd. In the case where the fibrous reinforcement wascontained, the pellet was injection-molded at a cylinder temperature of300° C., a mold temperature of 110° C., and a molding cycle of 30seconds. As a result, test pieces for UL Test having a length of 125 mm,a width of 13 mm, and thicknesses of 1.58 mm, 1.2 mm, and 1.0 mm weremolded.

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, and three steps of 1, 2, and 3 mm in thickness).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours. In the case where the fibrousreinforcement was not contained, the pellet was injection-molded at acylinder temperature of 280° C., a mold temperature of 80° C., and amolding cycle of 45 seconds using a Cycap M-2 with a clamping force of75 T manufactured by Sumitomo Heavy Industries, Ltd. In the case wherethe fibrous reinforcement was contained, the pellet was injection-moldedat a cylinder temperature of 300° C., a mold temperature of 110° C., anda molding cycle of 45 seconds. As a result, an ISO multipurpose testpiece (4 mm) and an ISO multipurpose test piece (3 mm) were molded.

<Evaluation of Flame Resistance>

The flame resistance was evaluated by performing UL Test in the samemanner as in Example V-1 using the test pieces for UL Test.

Tables 20 and 21 show the results.

<Evaluation of Reflectivity>

The reflectivity was measured using a three-millimeter-thickness portionof the flat test piece (having three steps of 1, 2, and 3 mm inthickness). The measurement was performed using Spectrophotometer CM3600d manufactured by KONICA MINOLTA HOLDINGS, INC. at a D65/10-degreeobserver with an SCl normal measurement mode. The reflectivity wasevaluated at a wavelength of 440 nm. Table 21 shows the results.

<Evaluation of Heat Resistance>

The deflection temperature under load was measured in accordance withISO 75-1 and ISO 75-2 using the ISO multipurpose test piece (4 mm) at aload of 1.80 MPa. Tables 20 and 21 show the results. In Tables 20 and21, the deflection temperature under load is given as “DTUL”.

<Evaluation of Bendability>

The bending stress and bending modulus were measured in accordance withISO 178 using the ISO multipurpose test piece (4 mm) at 23° C. Tables 20and 21 show the results.

<Evaluation of Impact Resistance>

The notched Charpy impact strength (unit: kJ/m²) was measured inaccordance with ISO 179 using the ISO multipurpose test piece (3 mm) at23° C. Tables 20 and 21 show the results.

TABLE 20 Comparative Example Example Unit V-5 V-5 Resin PC-1 parts by68.82 69.32 composition PC oligomer mass 10 10 Metal salt-1 0.08 0.08PTFE 0.1 0.1 PS 0.5 GF-1 15 15 GF-2 5 5 Mold-release 0.5 0.5 agent-2Flowability (MVR) cm³/10 min 11 10 Flame resistance V-0 V-1 (1.58 mm inthickness) DTUL ° C. 139 139 Bendability Elastic modulus MPa 5460 5520(load) Bending stress MPa 141 141 Impact resistance kJ/m² 9 8

TABLE 21 Comparative Example Example Unit V-6 V-6 Resin PC-1 parts by43.74 44.24 composition PC-2 mass 43 43 Metal salt-2 0.2 0.2 PTFE 0.40.4 PS 0.5 Titanium oxide 12 12 Mold-release 0.08 0.08 agent-2Mold-release 0.08 0.08 agent-3 Flowability (Q value) 10² cm³/ 15.3 14.7sec Flame 1.2 mm in thickness V-0 V-0 resistance 1.0 mm in thickness V-0V-0 Reflectivity % 94.5 94.8 DTUL ° C. 125 125 Bendability Elasticmodulus MPa 2400 2420 (load) Bending stress MPa 90 90

VI. Examples and Comparative Examples according to Sixth Aspect of thePresent Invention

The following components were used in Examples and Comparative Examples.

Polycarbonate resin [A1]: bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, viscosity-average molecularweight: 17000, structural viscosity index: 1.0

Polycarbonate resin [A2]: bisphenol A-type aromatic polycarbonate resinproduced by melt transesterification, viscosity-average molecularweight: 27000, structural viscosity index: 1.3

Polycarbonate resin [A3]: bisphenol A-type aromatic polycarbonate resinproduced by interfacial polymerization, viscosity-average molecularweight: 26000, structural viscosity index: 1.0

Metal salt compound [B]: potassium perfluorobutanesulfonate, productname: Bayowet C4 manufactured by LANXESS

Polysilane having an aryl group [C1]: cyclic polydiphenylsilane, productname: OGSOL SI-30-10 manufactured by Osaka Gas Chemicals Co., Ltd.,decaphenylcyclopentasilane, number-average molecular weight: 550

Other polysilane [C2]: straight-chain polydimethylsilane, number-averagemolecular weight: 2000

Fluoropolymer [D]: aqueous dispersion liquid of fluoroolefin resin, thecontent of PTFE: 60% by weight, Teflon (registered trademark) 31-JRmanufactured by DU PONT-MITSUI FLUOROCHEMICALS COMPANY, Ltd.

Light-diffusing agent [E1]: acrylic diffusing agent having an averageparticle size of 4 μm (spherical), Ganz Pearl GM-0205S manufactured byGANZ CHEMICAL Co., Ltd.

Light-diffusing agent [E2]: polymethylsilsesquioxane particles having anaverage particle size of 2 μm (spherical), Tospearl 120 manufactured byMomentive Performance Materials Inc.

Mold-release agent [F1]: pentaerythritol tetrastearate, VPG 861manufactured by Cognis Japan Ltd.

Mold-release agent [F2]: stearyl stearate, Unistar M9676 manufactured byNOF Corporation

Stabilizer [G1]: tris(2,4-di-tert-butylphenyl)phosphite, ADK STAB 2112manufactured by Adeka Corp.

Stabilizer [G2]: pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], Irganox 1010manufactured by Ciba Specialty Chemicals Co., Ltd.

Examples VI-1 and 2 and Comparative Examples VI-1 to 5 Production ofResin Pellet

The components described above were blended with each other at theratios (mass ratios) shown in Table 23 and mixed in a tumbler for 20minutes. The mixture was supplied to (TEX30HSST) having a single ventand manufactured by The Japan Steel Works, Ltd. and kneaded at a numberof screw revolutions of 200 rpm, a discharge rate of 15 kg/hour, and abarrel temperature of 270° C. After that, a molten resin extruded in astrand shape was rapidly cooled in a water bath and pelletized using apelletizer to obtain a pellet of a polycarbonate resin composition.

<Preparation of Test Piece>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 260° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain a test piece forUL Test having a length of 125 mm, a width of 13 mm, and a thickness of1.6 mm ( 1/16 inches).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, and 3 mm in thickness) and an ASTM test piece(notched test piece with a thickness of 3.2 mm).

<Evaluation of Flame Resistance>

The flame resistance of each polycarbonate resin composition wasevaluated as follows. The test piece for UL Test prepared by the methodabove was left in a thermostatic chamber having a temperature of 23° C.and a humidity of 50% for 48 hours, and the flame resistance wasevaluated in accordance with the UL 94 Test (Test for flammability ofplastic materials for parts in devices and appliances) specified by theU.S.A. Underwriters Laboratories (UL). UL 94V is a method for evaluatingflame resistance from the lingering flame time and dripping propertiesafter a burner flame has been applied, for ten seconds, to a test piecehaving a predetermined size and held in the vertical position. Toachieve flame resistance of V-0, V-1, and V-2, the criteria shown inTable 22 below need to be satisfied.

TABLE 22 V-0 V-1 V-2 Lingering 10 sec or shorter 30 sec or shorter 30sec or shorter flame time for each specimen Total lingering 50 sec orshorter 250 sec or 250 sec or flame time for shorter shorter fivespecimens Cotton ignition No No Yes by drips

The lingering flame time is the duration of flaming combustion of a testpiece after an ignition source has been moved away. The cotton ignitionby drips is determined by whether or not marking cotton placed about 300mm below the bottom of the test piece is ignited by drips from the testpiece. Furthermore, the case where even one of five specimens does notsatisfy the criteria above was evaluated as NR (not rated) because thecase does not satisfy V-2. Table 23 shows the results. In Table 23, thisis given as “Flame resistance”.

<Evaluation of Transparency>

The haze value (unit “%”) was measured with an NDH-2000 haze meter (D65light source) manufactured by NIPPON DENSHOKU INDUSTRIES Co., Ltd. inaccordance with JIS K-7105 using the flat test piece (3 mm in thickness)as a test piece. The haze value is used as the scale of turbidity ofresins. A smaller haze value means higher transparency, which ispreferable. Table 23 shows the results. In Table 23, this is given as“Transparency”.

<Evaluation of Hue>

With an SE-2000 spectrophotometer (C2 light source) manufactured byNIPPON DENSHOKU INDUSTRIES Co., Ltd., the YI value (unit “%”) wasmeasured by a transmission method in accordance with JIS K-7105 usingthe flat test piece (3 mm in thickness) as a test piece. The YI value(yellow index) is used as the scale of yellowing of resins. A smaller YIvalue means better hue, which is preferable. Table 23 shows the results.In Table 23, this is given as “Hue”.

<Impact Resistance>

The Izod impact strength (unit: J/m) was measured using the ASTM testpiece (notched test piece with a thickness of 3.2 mm) prepared above at23° C. in accordance with ASTM D256. Table 23 shows the results. InTable 23, this is given as “Impact resistance”.

TABLE 23 Comparative Comparative Comparative Comparative ComparativeExample Example Example Example Example Example Example VI-1 VI-2 VI-1VI-2 VI-3 VI-4 VI-5 Resin A1 parts 28.925 28.425 29.925 29.675 24.925 2928.925 composition A2 by mass 70 70 70 70 70 70 70 B 0.075 0.075 0.0750.075 0.075 0.075 C1 1 1.5 0.25 5 1 C2 1 Flame resistance V-0 V-0 V-2V-2 V-2 V-2 V-0 Transparency 0.6 0.6 0.5 0.5 0.7 0.5 99 Hue 1.2 1.2 2.01.4 2.0 1.2 31 Impact resistance 690 670 660 700 650 690 150

As is clear from Table 23, referring to Examples VI-1 and 2 andComparative Examples VI-2 and 3, the polycarbonate resin compositionscontaining predetermined amounts of metal salt compound and polysilanehaving an aryl group have high flame resistance, transparency, andimpact resistance and excellent hue. On the other hand, thepolycarbonate resin composition of Comparative Example VI-1 thatcontains only a metal salt compound and the polycarbonate resincomposition of Comparative Example VI-4 that contains only a polysilanehaving an aryl group have insufficient flame resistance. Furthermore,the polycarbonate resin composition of Comparative Example VI-5 thatcontains a polysilane not having an aryl group has insufficienttransparency and impact resistance. Accordingly, it was confirmed fromExamples and Comparative Examples described above that the effects ofimproving flame resistance, transparency, hue, and impact resistancecould be uniquely achieved through the configuration of the presentinvention.

Examples VI-3 and 4 and Comparative Examples VI-6 and 7 Production ofResin Pellet

The components described above were blended with each other at theratios (mass ratios) shown in Table 24 and mixed in a tumbler for 20minutes. The mixture was supplied to (TEX30HSST) having a single ventand manufactured by The Japan Steel Works, Ltd. and kneaded at a numberof screw revolutions of 200 rpm, a discharge rate of 15 kg/hour, and abarrel temperature of 270° C. After that, a molten resin extruded in astrand shape was rapidly cooled in a water bath and pelletized using apelletizer to obtain a pellet of a polycarbonate resin composition.

<Evaluation of Flowability (Q Value)>

The pellet obtained by the above-described production method was driedat 120° C. for 4 hours or more, and then the flow rate per unit time, Qvalue (unit: 10⁻² cm³/sec), of a composition was measured by a methoddescribed in Appendix C of JIS K7210 using a Koka-shiki Flow Tester at280° C. at a load of 160 kgf to evaluate the flowability. Note that anorifice having 1 mm in diameter and 10 mm in length was used. A higher Qvalue means higher flowability. Table 24 shows the results.

<Preparation of Test Piece>

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 260° C., a mold temperature of 80° C., and a moldingcycle of 30 seconds using a J50-EP injection molding machinemanufactured by The Japan Steel Works, Ltd. to obtain test pieces for ULTest having a length of 125 mm, a width of 13 mm, and thicknesses of 1.2mm and 1.0 mm.

The pellet obtained by the above-described production method was driedat 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 55 seconds using an M150AII-SJ injection molding machinemanufactured by Meiki Co., Ltd. to obtain a flat test piece (90 mm inlength, 50 mm in width, three steps of 1, 2, and 3 mm in thickness).

Similarly, the pellet obtained by the above-described production methodwas dried at 120° C. for 5 hours and then injection-molded at a cylindertemperature of 280° C., a mold temperature of 80° C., and a moldingcycle of 45 seconds using a Cycap M-2 with a clamping force of 75 Tmanufactured by Sumitomo Heavy Industries, Ltd. to obtain an ISOmultipurpose test piece (4 mm) and an ISO multipurpose test piece (3mm).

<Evaluation of Flame Resistance>

The flame resistance was evaluated by performing UL Test in the samemanner as in Example VI-1 using the test pieces for UL Test. Table 24shows the results.

<Evaluation of Turbidity>

In a one-millimeter-thickness portion and a two-millimeter-thicknessportion of the flat test piece (with three steps of 1, 2, and 3 mm inthickness), the turbidity was measured in accordance with JIS K-7136using an NDH-2000 turbidimeter manufactured by NIPPON DENSHOKUINDUSTRIES Co., Ltd. The turbidity is used as the scale of cloudiness ofresins. A lower turbidity value means higher transparency. Table 24shows the results.

<Evaluation of Diffusivity/Degree of Dispersion>

In a one-millimeter-thickness portion and a two-millimeter-thicknessportion of the flat test piece (with three steps of 1, 2, and 3 mm inthickness), the brightness was measured with GP-5 GONIOPHOTOMETERmanufactured by MURAKAMI COLOR RESEARCH LABORATORY under the conditionsthat incident light was at 0°, the elevation angle was 0°, thelight-receiving range was 0° to 90°, the luminous aperture was 2.0, andthe light-receiving aperture was 3.0. The diffusivity (%) was determinedfrom the following formula. The degree of dispersion indicates alight-receiving angle that provides 50% of brightness at alight-receiving angle of 0°, that is, 50% of brightness of a light beamwhich travels in a straight line after passing through the test piecefrom a light source. Table 24 shows the results.

Diffusivity (%)=100·[(brightness at a light-receiving angle of20°+brightness at a light-receiving angle of 70°)/{2·(brightness at alight-receiving angle of 5°)}]

<Evaluation of Heat Resistance>

The deflection temperature under load was measured in accordance withISO 75-1 and ISO 75-2 using the ISO multipurpose test piece (4 mm) at aload of 1.80 MPa. Table 24 shows the results. In Table 24, thedeflection temperature under load is given as “DTUL”.

<Evaluation of Bendability>

The bending stress and bending modulus were measured in accordance withISO 178 using the ISO multipurpose test piece (4 mm) at 23° C. Table 24shows the results.

TABLE 24 Comparative Comparative Example Example Example ExampleAbbreviation Unit VI-3 VI-4 VI-5 VI-6 Resin [A3] parts 17.48 17.98 18.4818.98 composition [A2] by mass 80.0 80.0 80.0 80.0 [B] 0.09 0.09 0.090.09 [D] 0.17 0.17 0.17 0.17 [C1] 1 1 [E1] 1 1 [E2] 0.5 0.5 [F1] 0.1 0.10.1 0.1 [F2] 0.1 0.1 0.1 0.1 [G1] 0.03 0.03 0.03 0.03 [G2] 0.03 0.030.03 0.03 Flowability (Q value) 10⁻² cm³/sec 4.6 4.6 4.5 4.5 Flame 1.2mm in thickness V-0 V-0 V-0 V-0 resistance 1.0 mm in thickness V-2 V-0V-2 V-1 Turbidity Hz (1 mm) % 98.2 99.1 98.0 99.1 Hz (2 mm) % 99.1 99.399.0 99.3 Diffusivity/ Diffusivity (1 mm) 29.3 46.9 26.9 45.6 Degree ofDegree of dispersion (1 mm) 21.2 36.5 19.5 34.7 dispersion Diffusivity(2 mm) 46.6 57.8 45.0 57.2 Degree of dispersion (2 mm) 36.8 51.2 34.850.3 DTUL ° C. 124 125 125 126 Bendability Elastic modulus MPa 2300 22802300 2380 (load) Bending stress MPa 97 97 96 99

It is clear from Table 24 that a satisfactory light-diffusing effect isachieved by blending a light-diffusing agent.

INDUSTRIAL APPLICABILITY

The first aspect of the present invention and the second aspect of thepresent invention can be utilized in a wide variety of industrial fieldsand are suitably used in the fields of, for example, electrical andelectronic devices and their components, OA equipment, informationterminals, mechanical parts, household electrical appliances, vehicleparts, architectural members, various containers, recreational equipmentand miscellaneous articles, and illuminators.

The third aspect of the present invention can be utilized in a widevariety of industrial fields and are suitably used in the fields of, forexample, electrical and electronic devices and their components, OAequipment, information terminals, mechanical parts, household electricalappliances, vehicle parts, architectural members, various containers,recreational equipment and miscellaneous articles, and illuminators, andfurthermore members for near-infrared laser welding, and members forsensing devices, exemplified by various automobile sensing devices, suchas face direction detection systems, rain sensors, various securitysystems, such as face recognition systems, fingerprint recognitionsystems, and vein recognition systems, and various informationcommunication devices, such as remote controllers and infraredcommunication devices, in automobile, electrical and electronic, andother precision apparatus fields.

The fourth aspect of the present invention, the fifth aspect of thepresent invention, and the sixth aspect of the present invention can beutilized in a wide variety of industrial fields and are suitably used inthe fields of, for example, electrical and electronic devices and theircomponents, OA equipment, information terminals, mechanical parts,household electrical appliances, vehicle parts, architectural members,various containers, recreational equipment and miscellaneous articles,and illuminators.

The present application is based on Japanese Patent Application filed onFeb. 9, 2009 (Japanese Patent Application No. 2009-026837), JapanesePatent Application filed on Mar. 10, 2009 (Japanese Patent ApplicationNo. 2009-055802), Japanese Patent Application filed on Mar. 26, 2009(Japanese Patent Application No. 2009-075456), Japanese PatentApplication filed on Apr. 20, 2009 (Japanese Patent Application No.2009-102103), Japanese Patent Application filed on Apr. 20, 2009(Japanese Patent Application No. 2009-102104), and Japanese PatentApplication filed on Apr. 21, 2009 (Japanese Patent Application No.2009-103168), which are incorporated by reference herein in theirentirety.

1. (canceled)
 2. A polycarbonate resin composition comprising: 0.01 to 1part by mass of a metal salt compound; and 0.01 to 5 parts by mass of apolysilane, relative to 100 parts by mass of a polycarbonate resin. 3:The polycarbonate resin composition according to claim 2, wherein thepolycarbonate resin contains 20% by mass or more of an aromaticpolycarbonate resin having a structural viscosity index N of 1.2 ormore. 4: The polycarbonate resin composition according to claim 3,wherein the aromatic polycarbonate resin having a structural viscosityindex N of 1.2 or more is an aromatic polycarbonate resin produced bytransesterification between an aromatic dihydroxy compound and acarbonic acid diester. 5: The composition according to claim 2, whereinthe polysilane has a Si—Si bond, and a linear, branched, cyclic, ornetwork structure, and at least one of structural units represented bythe following formulae (1) to (3):

wherein R¹, R², and R³ each independently represent a monovalenthydrocarbon group, a hydrogen atom, or a silyl group; a, b, and c eachindependently represent 0 or 1; and a plurality of R¹s, R²s, and R³s inthe main chain structure may each be the same or different. 6: Thecomposition of claim 5, wherein the polysilane is linear or cyclic andhaving a structural unit represented by the formula (1), wherein thelinear polysilane is represented by the following formula (4A), and thecyclic polysilane is represented by the following formula (4B):

wherein R¹, R², a, and b are as defined in the formula (1); R³¹ and R³²each independently represent a monovalent hydrocarbon group, a hydrogenatom, or a silyl group; s and t each independently represent 0 or 1; wrepresents an integer of 3 or more; and a plurality of R¹s and R²s inthe main chain structure may each be the same or different; wherein R¹,R², a, and b are as defined in the formula (1); x represents an integerof 4

to 12; and a plurality of R¹s and R²s in the main chain structure mayeach be the same or different. 7: The composition of claim 5, whereinthe degree of polymerization of the polysilane is 2 or more and 500 orless. 8: The composition of claim 5, wherein the degree ofpolymerization of the polysilane is 5 or more and 400 or less. 9: Thecomposition of claim 5, wherein the degree of polymerization of thepolysilane is 10 or more and 300 or less. 10: The composition of claim2, wherein the metal salt compound is an organic sulfonic acid metalsalt. 11: The composition of claim 10, wherein the organic sulfonic acidalkali metal salt is at least one selected from the group consisting ofa fluorine-comprising aliphatic sulfonic acid metal salt, afluorine-comprising aliphatic sulfonimide metal salt, an aromaticsulfonic acid metal salt and an aromatic sulfonamide metal salt. 12: Thecomposition of claim 11, wherein the fluorine-comprising aliphaticsulfonic acid alkali metal salt is present and is a perfluoroalkanesulfonic acid alkali metal salt. 13: The composition of claim 11,wherein the aromatic sulfonic acid alkali metal salt is present and is aparatoluenesulfonic acid alkali metal salt. 14: A polycarbonate resinformed product manufactured by shaping the polycarbonate resincomposition according to any one of claims 2 to 13.